5.

PENSTOCK CONSTRUCTION AND INSTALLATION

ITEM 5.1

CLEARING AND GRUBBING

(Same as Item 2.2)

ITEM 5.2

EARTH EXCAVATION

(Same as Item 2.3)

ITEM 5.3

ROCK EXCAVATION

(Same as Item 2.4)

ITEM 5.4

HAULING OF MATERIALS

(Same as Item 2.5)

ITEM 5.5
5.5.1

BACKFILLING
GENERAL

5.5.1.1

DESCRIPTION

This item shall consist of furnishing all materials, equipment and labor for
backfilling to install or construct the penstock and other accessories as
shown on the Plans and referred to in these specifications.
Backfill Term used to describe the material used in the fill zones of
excavation. Backfill shall consist of earth removed from excavation or sand
backfill approved by the Engineer. Debris or large rocks shall not be used as
backfill material.
Compaction The process whereby the density of a soil mass is increased by
mechanical, usually dynamic means. This typically involves tamping, rolling,
or vibration, or a combination of these processes. This will result in
relocation of soil particles and the expulsion of air from the soil mass, but
usually without significantly altering the amount of water in the soil.
5.5.2

MATERIAL REQUIREMENTS

Except as otherwise specified by the Engineer, the material excavated shall be

used as backfill material.
No large stones or debris shall be in the trench at any point. All backfill
materials shall be free from cinders, refuse, sod, organic materials and other
materials which in the opinion of the Engineer is unsuitable. The trench may be
backfilled by machine or by hand, but the work shall be done in such a way as to
prevent dropping of materials directly on top of the pipe or through any great
vertical distance onto the material covering the pipe so as not to cause
additional load on the pipe.

5.5.3

EXECUTION

5.5.3.1

PLACEMENT AND COMPACTION

The Contractor shall not place any backfill material until the Engineer has
inspected and accepted the placement of the bedding. The Contractor must
not place the overlay material until the concrete has obtained its initial set.
Backfill must not be placed within twenty four (24) hours of placing
concrete. Backfill shall be excavated granular material free of, debris,
organic matter, and rocks larger than four (4) inches across their greatest
dimension.
All compaction shall be by hand operated, plate type, vibratory, or other
suitable hand tampers in areas not accessible to larger rollers or
compactors. Extreme care shall be taken to avoid damage to conduits, pipes,
and any appurtenances.
The backfill material shall be placed and compacted in layers not exceeding
two hundred (200) millimeters loose thickness, and shall be moisture
conditioned as required to facilitate adequate compaction.
The Contractor is responsible for monitoring and rectifying any subsidence
that occurs as a consequence of the Works. The Contractor shall pay any
damage caused as a consequent of subsidence.
5.5.4

MEASUREMENT/BASIS OF PAYMENT

The volume that is to be backfilled to be paid for will be the volume of fill
acceptably cleared in conformity with the plans or as directed by the Engineer.
The accepted quantities, measured as prescribed above shall be paid for at the
contract unit price for each of the particular pay items listed and included in the
Bill of Quantities. The payment shall constitute full compensation for the
removal and disposal of cleared and grubbed materials including all labor,
equipment tools and incidentals.

ITEM 5.6

REINFORCING BARS GRADE 40

(Same as Item 2.8)

ITEM 5.7

FORM/DEFORM WORKS

(Same as Item 2.9)

ITEM 5.8

CONCRETING WORKS (3000 PSI)

(Same as Item 2.10)

ITEM 5.9
5.9.1

STEEL PIPE FABRICATION AND INSTALLATION

GENERAL

5.9.1.1

DESCRIPTION

This item shall cover all related Specifications for the supply, fabrication and
installation of steel pipes.
5.9.2

CONTRACTORS SCOPE

The Contractor shall supply, install, test and commission fully operational low
pressure steel pipes. Methodology shall be submitted to the Engineer as
instructed as well as the material specification of the pipe taking into account
the requirements specified herein.
Plans are in accordance with the provisions of these Specifications or as
instructed by the Engineer.

5.9.3

MATERIAL REQUIREMENT

Quality in all materials shall be ensured to meet all required parameters as

shown on the designs. Ultimate strength, elasticity limit, ductility, hardness,
durability, suitability for the intended service and best engineering practice shall
be considered. All materials shall comply with the latest applicable standards of
the ASTM, unless otherwise specified or approved by the Engineer.
Steel plates declared by the Engineer to have been defective at the time of
delivery will be replaced by the Contractor with all costs of replacement endured
by the Contractor. All materials that develop defects during or after fabrication
shall be rejected notwithstanding that they have previously passed specified
tests and inspections, and met the applicable requirements stated herein.
The size and thickness indicated in the Plans shall be adopted. Furnish suitable
and compatible anchors and pipe sleepers and fasteners that support the pipes.
a. Corrosion Resistance
The pipes shall have the best performance with respect to inhibiting
corrosion caused by natural environmental action. Rust converter will be
applied to pipes prior to application of red oxide paint. The Contractor shall
provide adequate corrosion protection for the works in accordance with
Section Surface Finishes, of these specification.
b. Materials Environmental Compatibility
The Contractor shall select the materials in consideration of its
environmental impact, including such effects as noise, vibration, and air
pollution, adaptability to recycling from the viewpoints of resource
management and environmental damage reduction as well as its harmony
with the local ecology.
c. Fabrication of Pipe
The Contractor shall supply/fabricate and install steel pipe. Welding and
cutting works shall be in accordance with all welding specification as stated
in this Specification.
d. Joints

Joints shall be fabricated accurately for close fit. Weld exposed joints
continuously unless otherwise indicated or approved. Dress exposed welds
flush and smooth. All welds shall be according to the applicable provisions as
stated herein.
e. Procedure for Installation of Embedded Items
Temporarily brace and secure items which are to be built into concrete.
Isolate non ferrous metal surfaces to be permanently fastened in contact
with ferrous metal surfaces, concrete, or masonry by coating non ferrous
metal surfaces with bituminous mastic, prior to installation
Fit and set fabricated metal work accurately in location, alignment, and
elevation. Securely fastened in place.
5.9.4

MEASUREMENT/BASIS OF PAYMENT

The method of measurement is as per accomplishment of installed steel pipes.

Fabrication, supply and installation of pipes shall be included in the Bill of
Quantities.
The quantities measured as prescribed above shall be paid for at the contract
unit price of the pay item that is included in the Bill of Quantities. Payments
shall be the compensation for all materials, labor, equipment, tool, and
incidentals to complete the work prescribed in this item.

ITEM 5.10
5.10.1

PENSTOCK PIPELINE SUPPORT FABRICATION AND INSTALLATION

GENERAL

5.10.1.1

DESCRIPTION

This item shall consists steel structures of any structural shape as shown
on the Plans approved by the Engineer. The structure will rest on pedestal
with a given height as required on site.
5.10.2

CONTRACTORS SCOPE

The Contractor shall be responsible for the accurate location of all steel works
including items used to attach materials to other parts of the work.
The Contractor shall see to it that any or all items of work which, are to be built
into the work of other trades are installed at the proper time.
The Contractor shall notify the Engineer if the steel work shall be fabricated in a
shop other than the site, so that arrangements can be made together with the
Engineer in the inspection of the delivered materials and in the fabrication of the
steel work.
5.10.3

SUBMITTALS

Furnish complete detailed fabrication and erection shop drawings including

details of all connections for review and approval of the Engineer.
The Engineer will review all shop drawings. Re submit if any corrections are
required.

5.10.4

MATERIAL REQUIREMENTS

Furnished materials, tools, equipment, labor and other services required to

complete fabrication and erection of all structural steel structures shall be
administered by the Contractor.
Where so indicated on the Plans, structural members shall be joined by welding.
The welds shall be of size and type indicated and shall be made by competent
welders.
5.10.4.1

DELIVERY

Shipping statements shall be delivered in the jobsite. The Engineer shall

inspect the materials per delivery and may request additional tests on
the materials delivered, if in their opinion, there is reasonable doubt as
to the materials specification. The fabrication and delivery of the
fabricated structural steel should conform to the Approved Schedule of
Erection and items such as anchor bolts, anchorage and other that have
been placed in concrete which shall be in the jobsite before such concrete
structural member is poured. Erection marks shall be painted on
structural steel members and fabricated sections. Small structural
members such as rivets, bolts, nuts, washers, etc., should be shipped
and kept in properly marked, suitable containers.

5.10.5

EXECUTION

5.10.5.1

WELDING TECHNIQUE

Conform the technique of welding employed in terms of quality and

aesthetic of the weld and the method used in correcting defective work to
the requirements of the Standard Code for Welding in Building
Construction of the American Welding Society.
The following procedures shall govern in all welding processes unless
otherwise initiated by the Engineer.
a. Surfaces to be welded shall be free from loose scale, slag, rust, grease,
paint, and any other foregoing material except that mill scale which
withstands vigorous wire brushing may remain.
b. Prepare edges by gas cutting, whenever practicable, cut by a
mechanically guided torch.
c. Let gas cut edges which will be subjected to substantial stress or which
are to have weld metal deposited on them be free from gauges. Remove
by grinding any gouge that remains from cutting.
d. Shape all re entrant corners notch free to a radius of at least twelve
(12) millimeters or one half () inches.
e. Bring in to a close contact as practicable parts to be fillet welded and in
no event separate by more than four (4) millimeters (3/16 inches). If the

separation is one (1) millimeters (1/16 inches) or greater, increase the

size of the fillet welds by the amount of the separation.
f. Never exceed the separation between laying surfaces of lap joints and
butt joint on a backing structure by one and five tenths (1.5)
millimeters (1/16 inches).
g. Bring the fit of joints at contact surfaces which are not completely
sealed by welds, close enough to exclude water after painting.
h. Align all abutting parts to be welded carefully. Correct misalignment
greater than three (3) millimeters (1/8 inches) in making the correction,
never draw parts into a slope sharper than two (2) degrees 11
millimeters in 300 millimeters (7/16 inches in 12 inches).
i. Position the work for flat welding whenever practicable.
j. In assembling and joining parts of structure or of built up members,
avoid unnecessary distortion and minimize shrinkage stresses, where it
is impossible to avoid high residual closing welds in compression
elements.
k. In the fabrication of cover plated beams and built up members, make
all shop splices in each component part before such is welded to other
parts of the member.
l. Let all complete penetration butt welds made by manual welding except
when produced with the aid of backing material or welded in the flat
position from both sides in square edge material not more than seven
(7) millimeters (5/16 inches) thick with opening not less than one half
() the thickness of the thinner part joined, have the root of the initial
layer gouged out on the back side before welding is started on the side.
Weld so as to secure sound metal fusion throughout the entire cross
section. With butt welds made with use of a backing of the same
material as the base metal, have the weld metal thoroughly fused with
the backing material.
m. Backing strips may be removed by gouging or gas cutting after welding
is completed, provided no injury is done to the base metal and weld
metal. Weld metal surface is left flush or slightly convex with full throat
thickness.
n. Terminate butt welds at the ends of a joint in a manner that will ensure
soundness.
o. Where possible, do the latter procedure by the use of extension bars or
run off plates. Remove extension bars or run off plates upon
completion of the welds. Make the ends of the welds smooth and flush
with abutting parts.
5.10.5.2

BOLTS

a. Tighten all bolts to a bolt tension not less than the proof load given in
the applicable ASTM specifications for the type of bolt used.

b. Do tightening with properly calibrated wrenched or by the turn of

nut method.
c. Let completed member be free from twist, bends and open joints. Sharp
or bends shall be a cause of rejection of materials.
5.10.5.3

PAINTING

a. Clean all steel work specified for painting by hardware brushing, or

other methods chosen by the fabricator for cleaning loose mill scale,
lose rust, weld slag, or flux deposit, dirt and other foreign matter after
inspection, approval and before leaving the shop.
b. Give all steel work that is to be encased in concrete two coat of epoxy
zinc chromate paint. Clean oil or grease with solvent cleaners. Remove
dirt and foreign materials through sweeping with a fiber brush.
c. Remove oil and grease deposits by solvents.
d. The Contractor shall provide adequate corrosion protection for the
works in accordance with, Section of this specification.
5.10.5.4

TESTS AND INSPECTION

All expenses for testing and inspection shall be shouldered by the

Contractor.
5.10.5.4.1

VISUAL INSPECTION OF WELDING

After the welding is accomplished, hand or power wire brush welds,

and thoroughly clean them before the inspection. Welds shall be
inspect to detect flaws such as undercut, overlap and other surface
flows. Magnifier devices shall be used under strong, adequate light
for surface cracking, porosity, and slag inclusion; excessive
roughness; unfilled craters; gas pockets; undercuts; overlaps; size
and insufficient throat and concavity. Inspect the preparation of
groove welds for adequate throat opening and for snug positioning of
the backup bars.

5.10.5.4.2

NONDESTRUCTIVE TESTING

The following methods for Nondestructive Testing can be adopted as

specified herein considering utmost into account the Engineers
decision.
a. Liquid Penetrant Inspections a dye must be applied to the
weld. After a few minutes, the dye should be cleaned from the
weld and a developer is applied. Any dye trapped in a flaw is
developed, revealing the location of the flaw.
b. Magnetic Particle Inspections the surface must be cleaned
first before magnetic particles are applied to the surface. Then

a strong magnetic field is applied. The fine magnetic particles

are drawn toward any flaw at the surface very near the surface
of the part.
c. Ultrasonic inspections This method can locate internal flaws
using sound waves.
d. X ray Inspections film is placed on one side of the part to
be inspected. X rays pass through the part and expose the
film. After the film is developed, any flaw in the weld can be
observed.
e. Air pressure/Water Pressure Leak Tests this method is best
for pipes that are to contain liquid or gasses.
Reference to AWS D1.1 Test locations shall be selected by the
Engineer but shall not be less than twenty five (25) percent of the
total number of joints. If more than twenty (20) percent of welds
contain defects, all welds shall be tested by ultrasonic testing,
magnetic particle testing shall be used only in areas inaccessible to
ultrasonic testing. Retest defective areas after repair.
5.10.5.5

IDENTIFICATION

a. Mark to identify the ASTM Specifications of steel for main components.

b. Identify such steel in completed members or assembles by painting
designation of the place over any shop coat of paint, prior to shipment
from fabricator plant.
5.10.5.6

ERECTION

5.10.5.6.1

GENERAL

The Contractor shall schedule, coordinate and sequence structural

steel erection in cooperation with the delivery of the structural steel
by the structural steel fabricator. The Contractor shall take special
care in unloading, handling and erecting the steel. Avoid any
activities that will cause distortion to the steel member. Tack welds
shall be ground smooth and holes shall be filled with weld metal or
body solder and smoothed by grinding or filling. Any structural steel
components that in the opinion of the Engineer have been damaged
or otherwise rendered useless by the improper handling by the
Contractor shall be replaced by the Contractor at his own expense.
5.10.5.6.2

BRACING

The frame of the steel structure shall be carried up true and plumb
and temporary bracing shall be introduced wherever necessary to
take care of all loads to which the structure maybe subjected,
including equipment and the operation of the same. Such bracing
shall be left in place as long as may be required for safety. Wherever
of piles of materials, erection equipment or other loads are varied
during erection, proper provisions shall be made to take care of
stresses resulting from such loads. As erection progresses, the work

shall be securely bolted, or welded, to take care of all dead load, wind
and erection stresses.
5.10.5.6.3

ALIGNMENT

No riveting, permanent bolting or permanent welding shall be done

until the structure has stiffened with the resulting stresses properly
aligned.
5.10.5.6.4

FIELD WELDING

Any shop paint on surface adjacent to joints to be field welded shall

be wire brushed, to reduce paint film to a minimum.
5.10.5.6.5

WORKMANSHIP

Structural steel sheets, members and struts/columns shall be

aligned, plumbed, straight in fabrication, welding and installation.
After erection, all unpainted areas including any marred or damaged
surfaces shall receive one coat of same rust inhibitive paint as used
in the shop painting.
5.10.6

MEASUREMENT/BASIS OF PAYMENT

This item will be paid as indicated in the contract which is per accomplishment
or can be converted into a lump sum basis.
The accepted quantities, measured as prescribed above shall be paid for at the
contract unit price for each of the particular pay items listed and included in
the Bill of Quantities. The payment shall constitute full compensation for the
fabrication, installation and supply of materials including all labor, equipment
tools and incidentals necessary to complete the work prescribed in this item.

ITEM 5.11
5.11.1

EXPANSION JOINTS FABRICATION AND INSTALLATION

GENERAL

5.11.1.1

DESCRIPTION

This item shall include complete supply, fabrication, and installation of

the expansion joints to identified location as shown on Plans or as
specified by the Engineer.
5.11.2

EXECUTION
The material shall be made of A36 steel and an approved kind of
sealer for the joints either a rubberized or compact cork material.
Bolts shall conform on the Drawings in terms of size and materials.
The bolts shall be made of required tensile strength steel.

5.11.3

MEASUREMENT/BASIS OF PAYMENT
Payment will be made as a lump sum basis or as per quantity
installed.

The installed item will be tested to assure that there is no leak and
shall be paid for at the Contract unit price for the expansion joint
pay item that is included in the Bill of Quantity, which price and
payment shall be for full compensation for furnishing all labor,
equipment, tools and incidentals necessary to complete the Work
prescribed in this item.