Drainage QCS

QCS 2014 Section 08: Drainage Works Page 1
Part 01: General
1 GENERAL ............................................................................................................... 2
1.1 SUMMARY .............................................................................................................. 2
1.1.1 Scope 2
1.1.2 References 2
1.1.3 Definitions 2
1.1.4 System Description 3
1.1.5 Submittals 3
1.1.6 Quality Assurance 5
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1.1.7 Site in Private Lands 5
1.1.8 Inspection and Handover Procedure 5
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1.2 TESTING OF MATERIALS ...................................................................................... 5
1.2.1 Materials Generally 5
1.2.2 100 Day Acid Test 6
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1.3 IMPLEMENTATION ................................................................................................. 7
1.3.1 Site Information 7
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1.3.2 Health and Safety 7
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1.3.3 Setting Out of the Works 10
1.3.4 Inspection of Works 10
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1.3.5 CCTV Survey 11
1.3.6 Compensation for Damage to Property 12
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Part 01: General
1 GENERAL
1.1 SUMMARY
1.1.1 Scope
1 This Section includes specifications for the construction and rehabilitation of sewerage,
surface water drainage and treated sewage effluent pipelines, piping, pipeline appurtenances
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and sewage treatment plants.
2 This Part includes general requirements basic to this Section and common to its Parts.
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3 Related Parts and Sections are as follows:
This Section
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Part 10, Pipeline Cleaning and Inspection Survey
Section 1, General
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Section 5, Concrete
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Section 6, Roadworks
Section 9,
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Mechanical and Electrical Equipment
Section 10, Instrumentation, Control and Automation
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Section 21, Electrical Works.
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1.1.2 References
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1 Documents of the following agencies are referred to in this Section:

American National Standards Institute, ANSI
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American Society for Testing and Materials, ASTM

American Water Works Association, AWWA
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British Standards Institution, BS

Euro Norms, EN
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Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance Section
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National Joint Health and Safety Committee for the Water Services, UK
International Organization for Standardization, ISO
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Swedish Standards Commission, SS

Water Research Centre, WRC, UK
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2 The following standards or revised/updated versions and other documents are referred to in
this Part:
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BS 6100 ......................Glossary of building and civil engineering terms

BS 8010 ......................Pipelines
BS EN 752 ..................Drain and Sewer Systems outside buildings
1.1.3 Definitions
1 The following definitions apply generally to this Section. These and other definitions included
in this Section are based, where applicable, on BS 6100, Part 2.
(a) Surface water: Water that flows over, or rests on, the surface of buildings, other
structures or the ground; the definition is extended to include groundwater.
Part 01: General
(b) Sewage: Contents of a sewer that does not solely convey surface water.
(c) Treated sewage effluent (TSE): Effluent from a sewage treatment works following
completion of treatment of sewage and disinfection of the treated sewage effluent to
attain a water quality standard suitable for reuse for selected purposes.
1.1.4 System Description
1 Unless otherwise specified herein or elsewhere in the Specification, designated in the Project
Specification, or directed by the Engineer, the material, equipment and systems to be
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provided under this Section shall:
(a) be capable of providing the required level of service
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(i) under the climatic conditions in Qatar as stated in Section 1
(ii) in handling the process fluids and materials of the prevailing and indicated
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(iii) quality and quantity and variations thereof
(iv) under the prevailing and indicated characteristics and quality of the natural and
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(v) process environments and process materials
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(b) comply with the provisions of BS EN 752, BS 8010, and BS 8301.
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1.1.5 Submittals
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General
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1 The Contractor shall submit to the Engineer for approval all drawings and data including
samples, calculations, schedules, certificates and other submittals specified in Section 1, this
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Section, the Project Specification, and required by variations. Submittals shall be in

accordance with the procedures specified in Section 1, in this Part and in the other Parts of
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this Section.
2 The Contractor, shall be responsible for preparing final record drawings relating to the civil,
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structural and architectural aspects of the Works. Mechanical, Electrical and ICA record
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drawings shall be provided by the Contractor as required by Section 1 Part 21.

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3 During the course of the Works, the Contractor shall maintain a detailed record of all
changes in order to facilitate accurate preparation of record drawings and to ensure that
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these drawings are in all respects a true record of the installation.
4 The Contractor shall provide the Engineer or his nominated representative drawings and a
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photocopy of each schedule correctly and neatly modified in red ink to truly represent the
Works constructed. These shall be submitted to the Engineer or his nominated
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representative for approval before the contract completion date.
5 If any drawing is not approved, it shall be returned to the Contractor with marked indications
of the additional information required.
6 In addition the Contractor shall complete the Drainage Affairs Network Record Sheets in the
prescribed format but not necessarily limited to, the following Record Sheets as applicable in
both hard copy and electronic copy in a widely used Data Exchange Format (DXF) textual
(i.e. .mdb, .xls or similar approved) format. Electronic format record sheets shall be obtained
from the Engineer or his nominated representative.
Part 01: General
PIPE LINE AND APPURTENANCES PUMPING STATIONS

a) Manhole Record (2 pages) a) Pumping Station Well Inventory Sheet
b) Discharge Chamber Record (2 b) Pumping Station Hoist Inventory Sheet

pages)
c) Sewer Record c) Pumping Station Motor Inventory Sheet
d) Valve Inventory d) Pumping Station Penstock Inventory Sheet
e) Valve Chamber Survey (3 pages) e) Pumping Station Data Sheet
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f) TSE Pipeline Record f) Pumping Station Pump Inventory Sheet
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g) Rising Main Record g) Pumping Station Shaft Inventory Sheet
h) TSE Tower Record h) Pumping Station Valve Inventory Sheet
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i) TSE Distribution Chamber i) Pumping Station Ventilation Inventory Sheet
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j) Overflow Pipe Record j) Pumping Station Fan Inventory Sheet
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k) TSE/Rising Main Fittings Record k) Pumping Station Generator Sheet
l) House Connection Record l)

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Pumping Station Control Panel Inventory
Sheet 1
m) Pumping Station Record m) Pumping Station Control Panel Inventory
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Sheet 2
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n) Gully Record n) Pumping Station Control Panel Inventory

Sheet 3
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o) CCTV record sheet and video tape o) Pumping Station Actuator Sheet
p) Pumping Station Air Conditioner Sheet

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7 The Contractor shall be deemed to have included all provisions within his Tender should the
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above list be altered by PWA from time to time.

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8 Individual Record Sheets shall be prepared for each length of sewer, TSE pipeline, rising
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main and overflow pipe, each manhole and house and gully connection, and shall be
submitted to the Engineer or his nominated representative for approval after which they shall
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become the property of the Employer.
9 Record sheets for pipelines (c, f, g, i, j, k, l & n above as appropriate), and record sheets for
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any other work that is to be covered up, shall be presented for approval prior to covering up
the works. Backfilling will not be permitted prior to the record sheets being approved.
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10 Record sheets for work of an exposed nature that can be later verified by the Engineer or his
nominated representative may be submitted up to 14 days after the work has been carried
out.
11 Photocopies of record sheets relating to work carried out since the previous valuation shall
be submitted with each interim valuation application.
12 No valuation of sections of work will be considered in the absence of completed record

sheets for the work in question.
Part 01: General
13 A Certificate of Completion will not be issued until a complete set of Record Sheets endorsed
by the Engineer’s Site Representative has been presented to the Engineer.
14 Blank hard copy Record Sheets, as detailed in sub-clause 6 above will be supplied by the
Engineer.
15 The Contractor shall accurately locate by co-ordinates to the Qatar National Grid, the centre
of all covers of manholes and chambers constructed under this project or to which any work
whatsoever has been undertaken under this project. The Contractor shall also locate by co-
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ordinates the position of buried bends and fittings on pressure mains. Where pipelines are
not laid to straight lines between chambers or fittings the co-ordinates of every pipe joint shall
be recorded prior to covering up the pipeline. Where flexible pipes are used coordinates
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shall be at 10m intervals.
16 All Survey works shall be undertaken by Survey Company approved by Engineer.
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1.1.6 Quality Assurance
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1 Materials and products shall be furnished by approved suppliers as designated in the
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Contract and Project Specifications.
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Survey work for obtaining record sheet data and the compilation of the data shall be carried
out by approved prequalified surveying companies designated in the Contract or Project
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Specification.
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1.1.7 Site in Private Lands

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1 The Employer will serve the necessary notices to permit pipelines to be constructed in private
land in accordance with the agreed programme of work. The Contractor shall not enter those
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lands without the Engineer’s permission. The Contractor shall temporarily fence the Site in
private lands to the satisfaction of the Engineer and the Contractor’s operations shall be
confined within the fenced area. The Contractor shall use the Site for the purposes of
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constructing the Works only.

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1.1.8 Inspection and Handover Procedure

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1 The inspection and handing over of the Works to the Employer shall be in accordance with
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the procedure specified in Section 1, and, Clauses 1.3.4 and 1.3.5 of this Part.
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1.2 TESTING OF MATERIALS
1.2.1 Materials Generally

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1 All materials to be used in contact with sewage or its atmosphere must be shown to
withstand corrosion. In the absence of satisfactory evidence of equivalent testing results,
materials will be required to pass the 100 day acid test as detailed in Clause 1.2.2 of this
Part.
Part 01: General
1.2.2 100 Day Acid Test

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1 Based on the results at 100 days, materials shall be deemed to be unsuitable for use in
contact with sewage or sewer atmosphere in the opinion of the Engineer the tested samples
fail to satisfy any of the following requirements:
withstand corrosion and in the absence of satisfactory evidence of equivalent testing results
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will be required to pass successfully the 100 day acid test as detailed in this Specification.
The test shall be carried out by an approved laboratory, experienced in undertaking the test.
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withstand corrosion. Such materials may be divided into two categories:
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4 Category 1 Materials - material which serve a purpose other than protection (e.g. pipes and
pipe jointing materials)
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5 Category 2 Materials – materials which protect other (usually structural) corrodible materials
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(e.g. coating to step irons, GRP manhole liners, acid resistant mortar).
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Sample preparation and testing shall, as far as is possible, simulate the conditions to which
the materials will ultimately be subjected.
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7 Samples shall be taken and prepared in a manner to be approved by the Engineer. Care
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shall be taken in preparation of samples of non-homogenous materials to ensure that only

the face that will be exposed to the corrosive environment in the sewer is exposed to the acid
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during the testing.

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(a) Samples in Category I materials shall be cut from pipe/pipe joint samples selected by
the Engineer and cut ends adequately protected by a gel coat.
(b) Samples of Category II materials shall be generally prepared by coating a corrodible
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material with the protective coating to be tested.

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8 For each test two samples shall be prepared and indelibly marked with an identifying number.
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9 One sample shall be partially immersed in 10% V/V sulphuric acid maintained at a
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temperature of 50 C for 100 days. The concentration of acid shall be maintained by
preventing evaporation. In addition the strength of the acid shall be regularly checked and
the level and strength adjusted as necessary. The second sample shall be kept as a control.
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10 The test sample shall be visually inspected at weekly intervals. Interim reports on the
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condition of the sample shall be submitted to the Engineer by the laboratory following visual
inspections of the samples after 25, 50 and 75 days. Such reports shall include reference to
any changes in surface condition and colour of the samples, changes in colour of the liquid,
and any presence of any particles in the liquid.
11 If the interim report after 75 days is satisfactory the Contractor may request the Engineer’s
approval to use of the material prior to completion of the 100 day acid test. Such approval
shall be solely at the discretion of the Engineer, and the use of the materials shall be entirely
at the Contractor’s risk. Any costs associated with the replacement of such materials, should
they subsequently fail the acid test, shall be borne by the Contractor.
Part 01: General
12 On completion of the test period, the sample tested in sulphuric acid shall be split or the
coating removed to determine the internal condition of the sample. The final test report shall
give full details of:
(a) The test procedure adopted.

(b) The surface condition of the samples before, during and after testing, listing the times
at which significant changes in appearance were noted.
(c) The internal condition of the sample.
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(d) Any changes in the solution.
13 Materials shall be deemed to be unsuitable for use in acid environments if the acid tested
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samples fail to satisfy any of the following requirements:
(a) Category 1 Materials - the surface of the samples shall not be significantly different in
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texture from the non-immersed control sample.
(b) Category 2 Materials -the underlying corrodible material shall not show any sign of
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corrosion.
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14 The surfaces of the samples shall not be significantly different in texture from the non-
immersed control sample. No change in surface hardness will be permitted, and no splits,
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cracks, blisters or delamination will be allowed.
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1.3 IMPLEMENTATION
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1.3.1 Site Information

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1 Notwithstanding any relevant information included or referred to in the Project Specification

or furnished by the Engineer, the Contractor shall be responsible for obtaining his own
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information on ground and subsoil conditions at the Site and the locations of all pipelines and
services within or near the Site.
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2 The Contractor shall complete a services information sheet for each section of the Works
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and shall submit the completed sheet for the Engineer’s approval at least seven days before
work is due to begin on that section. Work shall not begin on that section until the respective
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services information sheet has been approved by the Engineer.

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3 Blank services information sheets will be provided by the Engineer.

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1.3.2 Health and Safety
1 The requirements of this Clause are pursuant to or in addition to the health and safety
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requirements in Section 1 and Section 11. Safety requirements in relation to specific classes
of work are specified in other Parts of this Section.
2 The recommendations contained in ”Working with Sewage – The Health Hazards” Pbulished
by the Health & Safety Executive – http://www.hse.gov.uk/pubns/indg198.htm shall be
adhered to in respect of all work to be carried out in operational sewers, pumping stations
and sewage treatment works.
Part 01: General
3 Arrangements shall be made with Drainage Operation and Maintenance Department, Public
Works Authority before entering in or working on existing sewers and associated works. A
Permit to Work must be obtained from Asset Affairs Drainage Operations and Maintenance
Department prior to any works taking place .
4 The Contractor’s attention is drawn to the hazards involved in working in confined spaces
including sewers, manholes, inspection chambers, wet wells, pumping stations and ancillary
structures. The Contractor shall be responsible for ensuring that adequate precautions are
taken to ensure safe working conditions as well as the availability of safe tools and facilities.
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The Contractor shall issue his risk assessment to the Engineer for his approval prior to
applying for a Permit to Work at the site. This risk assessment shall meet but not be limited
to the requirements of this Part of this Section.
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5 The Contractor shall appoint a Safety Officer who shall be suitably qualified and experienced.
The Contractor shall ensure that the Safety Officer is available on Site during the mobilisation
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period and thereafter to train the Contractor’s personnel in safety operations. The work shall
not proceed unless such training has been accomplished to the Engineer’s approval.
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6 The Safety Officer’s main responsibilities shall be to
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(a) ensure that all the Contractor’s employees follow the agreed safety procedures
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(b) ensure that all employees are supplied with the appropriate safety/protective
equipment and that it is used and maintained as per agreed procedures
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(c) assist in carrying out of refresher safety training courses for working in confined
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spaces
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(d) investigate all accidents and dangerous occurrences, and where applicable, submit
reports recommending actions to be taken to prevent a recurrence.
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7 The Contractor shall provide and erect approved safety barriers around all unattended open
manholes and trenches. All manholes shall be covered with suitable temporary steel sheets.
Advance warning notice road signs shall be erected at least 50 m either side of areas where
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work is in progress.
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8 The need for adequate protection to the general public in the vicinity of the Works is
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stressed.
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9 Care must be exercised when working in or near live sewers, and tests must be made to
verify that no hydrogen sulphide or other toxic gases are present, before anyone enters an
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existing manhole or confined space.
10 Particular attention is drawn to the dangers of poisoning, asphyxiation or explosion while

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working in, or near, or inspecting pipelines, manholes, chambers, treatment units, pumping
stations, or any confined space. In this connection the Contractor must obtain appropriate
safety equipment and acquaint all personnel with the dangers involved, and precautions to be
taken, and shall regularly discuss with the Engineer's Representative the sufficiency of safety
precautions on site.
11 The following minimum precautions must be taken before entry into a manhole, chamber or
other confined space:
(a) Sufficient numbers of covers of manholes or chambers upstream and downstream of

the entry point shall be removed to ensure adequate ventilation.
Part 01: General
(b) The manhole or confined space must be thoroughly ventilated by mechanical air
blower prior to entry.
(c) Before entering the confined space the atmosphere shall be checked for the presence
of toxic gases, flammable gases, and oxygen level.
(d) The mechanical air blower must be kept close by the manhole or confined space that
has been entered.
(e) No naked lights, matches or lighters shall be used in a sewer or in close proximity to
an open manhole or chamber. All equipment shall be intrinsically safe.
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(f) The hydrogen sulphide level in the manhole or confined space must be continually
monitored. If the level rises the manhole or confined space must be evacuated
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immediately.
(g) All persons entering a manhole or confined space must wear a safety harness properly
rigged to the lifting frame.
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(h) At least two top men must be available to operate the air blower and lifting tackle in the
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event of an emergency. The top men shall keep in touch with the men in the sewer,
manhole, chamber or confined space by calling or signalling to them at frequent
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intervals. No person shall enter the confined space alone.
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Before entering any confined space, the atmosphere shall be checked for the presence of
toxic gases, flammable gases and oxygen level. The Contractor shall have on site in working
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order, sufficient calibrated gas monitors to continually monitor the atmosphere in all confined
spaces and in all areas adjacent to sewage where men are working.
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13 The Contractor will not be permitted to work in manholes, pipelines, or pumping stations if
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such gas monitors are not in use.

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14 The following equipment is to be made available throughout the Contract at each and every
entry point to a confined space.
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Safety Harness (not a safety belt) and ropes 1 No.

Lifting frame and tackle for safety harness 1 No.
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Gas monitor 1 No.

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Mechanical air blower with compressor and generator 1 No.

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15 Gas monitors shall incorporate the following features:
(a) (a) Continuous monitoring of oxygen level, with visual and audible high and low level
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alarms.
(b) (b) Continuous electrochemical monitoring of Hydrogen Sulphide with indication of the
gas concentration, and audible and visual alarms under the following conditions:
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(i) Time weighted average providing 8 hours exposure at the threshold limit value.
(ii) Time weighted average providing 10 minutes of exposure at short term
exposure limit, or ceiling value.
(iii) Exposures to ten times the threshold limit value.
(c) (c) Continual monitoring for flammable gas at intervals not exceeding 2 minutes.
Part 01: General
1.3.3 Setting Out of the Works
1 The following requirements are pursuant to or in addition to the requirements in Section 1.

The Contractor shall locate, by co-ordinates to the Qatar National Grid, the locations of the
elements of the Works. Pipelines shall be located by the position of the centre of manholes
and chamber covers. Pressure pipelines shall be located by the position of bends and fittings.
2 The execution of surveys, recording of data and preparation of record sheets shall comply
with the following requirements:
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(a) surveys shall be based on Qatar National Grid survey control points
(b) co-ordinates shall be located to within 0.1 m
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(c) co-ordinates shall be determined by radial (polar) observations using theodolite and
electronic distance measuring (EDM) equipment. The co-ordinates shall be checked
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by independent methods and the error shown to be within acceptable limits
(d) if required, additional temporary control points may be established as follows:
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(i) observations for additional temporary control points shall consist of at least two
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(ii) rounds of angles (on two faces) with a different zero setting for each round.
(iii)
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where applicable, distances shall be determined by trigonometric methods and
(iv) at least two rounds of vertical angles (on two faces) shall be observed.
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(v) positions of additional temporary control points shall be determined by

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(vi) reference to not less than three Qatar National Grid survey control points and
shall be proven to have standard errors of not more than  0.08 m.
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3 On completion of work, all observations, computations, sketches and any other

documentation used in determining the co-ordinates shall be submitted to the Engineer. A
daily log giving the number of additional control stations and manholes surveyed shall be
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maintained and submitted. A comprehensive report on the work carried out including
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methods used, problems encountered, solutions used and a full summary of the results shall
be submitted.
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4 The Engineers approval of the setting out shall be obtained before work on each element
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commences.
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5 The Contractor shall be deemed to have included all provisions within his tender for the
‘topographical survey information which should include: - features (fittings), manhole
chamber co-ordinates/levels in a widely used Data Exchange Format (DXF), accurate
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positional survey drawings (i.e. either.DWG or.DXF) layout files together with equally widely
used DXF textural (i.e. xls, .txt or similar approved).
1.3.4 Inspection of Works
1 The Contractor shall provide a safe and convenient means of access to the Works to enable
the Engineer’s inspections to be carried out.
2 The Contractor shall submit to the Engineer notice of work requiring inspection on a
completed Notice of Inspection Required form not less than 24 hours before requiring
inspection of those works. Blank forms will be provided by the Engineer.
Part 01: General
3 Requests for inspection by the Engineer shall be submitted for the following:
(a) setting out

(b) formation level of excavation
(c) pipelaying, bedding and testing
(d) base slabs
(e) manhole precast chamber rings in place before internal linings and external coatings
are applied
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(f) manhole concrete surround
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(g) formwork and reinforcing steel before concreting
(h) before backfilling of permanent Works
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(i) before reinstatement
(j) any other constructional operation that the Engineer may require.
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4 Works covered up or in any way made unavailable for inspection before the submission of
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the Notice of Inspection Required form or the Engineer’s approval to proceed shall be
uncovered at the Contractor’s expense. M
5 Prior to inspection, the Contractor shall submit his Quality Control plan (QC plan) / Inspection
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and Test Plan (ITP) in accordance with Section 1 Clause 7.6.3.
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1.3.5 CCTV Survey

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1 The Contractor shall on written instruction of the Engineer undertake a CCTV survey on
designated lengths of pipelines laid during the execution of the Works, including pipeline
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cleaning where necessary and submission of a Survey Report, as part of the final inspection
of the Works.
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2 The Certificate of Completion for the Works or part thereof shall not be issued until the CCTV
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Survey, including provision of the Survey Report, and any subsequent sewer remedial works
have been completed to the satisfaction of the Engineer.
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3 Should any length of the surveyed between adjacent manholes, or the manholes indicate
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failure to comply with the requirements of the Contract, the whole cost of any pipeline
cleaning, the CCTV Survey, Survey Report and any subsequent remedial works carried out
to the satisfaction of the Engineer shall be borne by the Contractor.
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4 The CCTV Survey shall be carried out by an approved specialist subcontractor designated in
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the Project Specification. The subcontractor shall provide suitable documentation to verify
previous experience in undertaking CCTV Surveys to the satisfaction of the Engineer.
5 Pipeline cleaning and CCTV surveys and reporting shall be carried out as specified in Part 10
of this Section.
Part 01: General
1.3.6 Compensation for Damage to Property
1 Before commencing any work on site, the Contractor shall undertake an extensive condition
survey of all properties adjacent to the proposed works. A detailed report including sketch
plans, schedules of defects and photographs shall be submitted to the Engineer for
agreement.
2 The Contractor shall not mark boundary walls to properties in any way whether deliberately
for identification purposes or accidentally. All markings, howsoever caused, shall be repaired
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and repainted. Sufficient area of wall shall be repainted to avoid a patchy appearance.
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END OF PART
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Part 02: Earthworks
2 EARTHWORKS ............................................................................................. 2
2.1 GENERAL ...................................................................................................... 2

2.1.1 Scope 2
2.1.2 References 2
2.1.3 Definitions 2
2.1.4 Trial Holes 3
2.1.5 Services Co-ordination 3
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2.2 EXCAVATIONS ............................................................................................. 3
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2.2.1 General 3
2.2.2 Surfaces 3
2.2.3 Materials 4
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2.2.4 Excavations to be Kept Dry 5
2.2.5 Access 5
2.2.6 Trench Excavations 6
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2.2.7 Appurtenant Structures for Pipelines 8
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2.2.8 Excavation in Roads 9
2.2.9 Excavation in Areas Other Than Road Reserves M 9
2.2.10 Support of Excavations 10
2.2.11 Slips and Falls and Excess Excavation 10
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2.2.12 Trimming and Levelling 11

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2.2.13 Excavations Not to be Left Open 11

2.2.14 Dewatering of Excavations 12
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2.3 BACKFILL .................................................................................................... 13

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2.3.1 Pipe Bedding 14

2.3.2 Pipe Surround 16
2.3.3 Geotextile Filter Membrane 16
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2.3.4 Backfilling Excavation 17

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2.3.5 Backfilling Excavations with Cement-Bound Granular Material 19

2.3.6 Backfilling Excavation with Flowable Fill (Foamed Concrete) 21
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2.3.7 Backfilling Next to Pipeline Structures 22

2.3.8 No-Fines Concrete as Trench Backfill 22
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2.4 REINSTATEMENT OF SURFACES ............................................................ 22

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2.4.1 Reinstatement within the Highway 22

2.4.2 Reinstatement of Surfaces Other Than in the Highway 22
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2.5 EXISTING SERVICES ................................................................................. 23
2.6 BLASTING ................................................................................................... 24
2.7 MISCELLANEOUS ...................................................................................... 26

2.7.1 Service Ducts 26
2.7.2 Formation of Bunds and Embankments 26
Part 02: Earthworks
2 EARTHWORKS
2.1 GENERAL
2.1.1 Scope
1 This Part includes earthworks for pipelines including, excavation, granular pipe bedding,
concrete protection of pipe, backfill and compaction, and service protection ducts to protect
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existing utilities.
2 Related Sections are as follows:
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This Section
Part 1, General
Part 3, Pipeline Installation
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Part 9, Trenchless Pipeline Construction
Part 10, Sewer Rehabilitation
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Part 12, Vacuum Sewerage System
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Section 1, General
Section 3, Ground Investigation M
Section 5, Concrete
Section 6, Roadworks
Section 12, Earthworks Related to Buildings
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Section 28, Landscaping.

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2.1.2 References
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1 The following standards and other documents are referred to in this Part
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BS 410........................Test sieves
BS 1924......................Stabilised materials for civil engineering purposes
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BS 6031......................Code of practice for earthworks

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BS EN 12620..............Aggregates for concrete

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BS EN ISO 10319 ......Geosynthetics

BS EN ISO 11058 ......Geotextiles and geotextile-related products
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BS EN ISO 12236 ......Geosynthetics

BS EN ISO 12956 ......Geotextiles and geotextile-related products
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Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance

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Section, Code of Practice and Specification for Road Openings in the Highway
2.1.3 Definitions
1 Trench excavation means excavation in all materials of whatever nature encountered for
trenches into which pipes, ducts or cables are to be laid, or manholes, chambers and
appurtenances constructed, and the term pipe shall mean pipe of all kinds and for whatever
purposes.
Part 02: Earthworks
2.1.4 Trial Holes
1 Trial holes for determining the location of existing services shall be excavated well ahead of
the trench excavation to such depths as necessary to determine and confirm the alignment
for the trench and the soil condition. The Contractor shall arrange for the refilling and
reinstatement of trial holes to be carried out immediately after the required information is
obtained. The reinstatement of trial holes shall be carried out to the approval of the Engineer.
2.1.5 Services Co-ordination
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1 In addition to the requirements of the relevant Parts of Section 1 and Part 1 of this Section,
the following paragraphs shall apply to services co-ordination for pipeline excavations.
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2 Notwithstanding any relevant information furnished by the Engineer, the Contractor shall be
responsible for ascertaining from his own inspection of the Site and the respective Utilities
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Service Departments and private landowners the position of all mains, pipes, cables, and
other services and facilities whether underground or overhead within or near the Site.
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3 Except as otherwise specified, the Contractor shall make arrangements necessary for
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carrying out the Works with the various Utilities Service Departments and private landowners.
The Contractor shall be responsible for any damage caused as a result of his omission in this
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respect, and for any damage caused by his failure to notify the Engineer’s representative and
the agencies concerned immediately any service is encountered in the excavations.
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4 Work on existing services is specified in Subparts 2.4, 2.5 and 2.7 of this Part.
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2.2 EXCAVATIONS
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2.2.1 General
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1 The Contractor shall be deemed to have obtained additional site information in accordance
with Clause 1.3.1 of this Section.
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2.2.2 Surfaces
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1 Before the surface of the area to be excavated is disturbed the Contractor shall take and
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record levels of the area in the presence of the Engineer. At least two days notice shall be
provided to the Engineer.
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2 The demolition of existing works shall be in accordance with Section 2.
3 Except as otherwise designated in the Project Specification or directed by the Engineer,

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breaking out and restoration of existing surfaces and works shall be done in accordance with
the Code of Practice and Specification for Road Openings in the Highway published by the
Highway Maintenance Section, Civil Engineering Department, Ministry of Municipal Affairs
and Agriculture.
4 Surface materials shall be carefully stripped or otherwise removed and set aside for reuse,
restoration, or replacement as directed by the Engineer.
Part 02: Earthworks
5 Where the trench excavation crosses surface barriers such as fences and walls the
Contractor shall
(a) obtain the written approval of the Engineer before breaching the barrier
(b) minimise the size of the opening, where possible using a short heading
(c) carefully dismantle the barrier as necessary for reuse, replacement, or reinstatement
(d) provide temporary fencing for any removed parts of such barriers as directed by the
Engineer.
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2.2.3 Materials
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1 Selected excavated material shall be the most suitable portions of the excavated material
free from matter harmful to other materials in the works and which is capable of being
compacted to the specified density to form stable fill. The material shall also conform to the
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requirements mentioned in Clauses 3.3.2, 3.3.3 and 3.3.5 of Section 6.
2 It shall be the responsibility of the Contractor to locate suitable borrowed or imported fill
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material which may be necessary and to carry out such tests as the Engineer may require to
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demonstrate the suitability of the fill to be supplied. Imported fill shall be from a source
approved by the Engineer. Imported fill shall have the following properties
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(a) maximum stone size of 150 mm except as specified in Clause 2.3.2 of this Part
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(b) liquid limit less than 35 %
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(c) plasticity index of not more than 10.

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3 Excavated material unsuitable for use in the Works shall not be stockpiled on the Site.
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4 Disposal of excavated material not used in the Works shall be the responsibility of the
Contractor and shall be at a location approved by the relevant government agency.
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5 Excavated material shall not be stockpiled on road reservations nor at other locations
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designated in the Project Specification. The Contractor shall confine his operations to the
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working areas available to him for the construction of the Works particularly where this is
located in roads or in other places to which the public has free access.
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6 Stockpiling materials on the Site or off the Site, as necessary, shall be the responsibility of
the Contractor. The stockpiling of surplus excavated material or other debris on site is not
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permitted. All surplus excavated material shall be removed from site to approved disposal
sites. All dump trucks transporting waste shall be fully covered to prevent discharge of the
contents.
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7 Any temporary storage alongside the trench excavation shall be to stable slopes and heights
and deposited in such a manner that no damage and as little inconvenience as possible is
caused. Backfilling materials shall be fenced off and continuously irrigated with water to avoid
dust and pollution.
8 Where the nature of the excavated material is suitable, the Contractor’s temporary storage
as aforesaid shall include for separate storage as the Engineer may direct of the various
grades of materials hereinafter specified for the refilling and surface reinstatement of trench
or structure excavation, namely, soft material, coarse material, hard material and topsoil. The
Contractor is to agree a screening location with the concerned municipality.
Part 02: Earthworks
9 The screening of trench excavated material will not be permitted on site without the written
approval of the Engineer.
10 The Contractor shall post signs indicating proposed use of material stockpiled. Post signs
shall be readable from all directions of approach to each stockpile. Signs should be clearly
worded and readable by equipment operators from their normal seated position.
11 The Contractor shall not stockpile excavated materials near or over existing facilities,
adjacent property, or completed work, if weight of stockpiled material could induce excessive
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settlement.
12 The Contractor shall obtain all necessary approvals for the sites of borrow pits and quarries.
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All borrow pits shall be left in a tidy and regular state. The Contractor shall ensure that pits
are self-draining at all times and do not constitute a nuisance and danger to the public.
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2.2.4 Excavations to be Kept Dry
1 The Contractor shall keep excavations free of water, sewage, and other liquids whether
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affected by tides, floods, storms, or otherwise so that the Works shall be constructed in dry
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conditions.
2
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The Contractor shall keep the subsoil or accumulated water or sewage at a level lower than
the bottom of the permanent work until trench backfilling is complete or for such other period
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directed by the Engineer.
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3 Measures taken by the Contractor for the control of water shall conform with the
specifications of this Part.
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2.2.5 Access
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1 A minimum clear carriageway width of 3 m shall be maintained for vehicular traffic unless
otherwise approved by the Engineer.
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2 Excavations in roads shall be organised to reduce to a minimum the interval between

opening up and backfilling excavations.
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3 The Contractor shall supply, post and display at all entrances to all properties a Notice of
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Excavation before any excavation is undertaken in front of or in the vicinity of the property.
The notice shall be in the form of a self- adhesive glossy sticker which shall be easily
removable. A typical sample is shown in Section E of the Contract Documents. The
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Contractor shall remove the label after all the excavation has been backfilled.
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4 Should cess-pits of other artificial obstructions be encountered in the excavation either above
or below ground level the Contractor shall forthwith advise the Engineer’s Representative
thereof and execute at his own cost such work as may be ordered.
5 The Contractor shall allow for laying pipes through any cess pits or septic tanks encountered
along the route. Pipes shall be laid such that joints occur either side of the structure or in a
manner approved by the Engineer’s Representative.
Part 02: Earthworks
2.2.6 Trench Excavations
1 The Contractor shall provide the necessary support of excavations. Details of excavation
support systems shall be submitted to the Engineer for review and approval at least sixty (60)
days before any excavation work commences.
2 Support of excavations shall be provided in accordance with BS 6031, except as otherwise

specified in this Part.
The term “necessary support of excavations” covers all normal methods of temporary
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3
support including timber, concrete, steel sheet piling, steel trench sheeting or other materials
as may be approved by the Engineer. Where excavation is carried out near or under an
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existing structure or any portion of the Work, the Contractor shall prevent damage due to
subsidence with methods approved by the Engineer.
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4 The maximum trench width shall be as given in Table 2.1 unless otherwise shown on the
drawings. The width of the excavation shall be increased if necessary to provide space for
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the trench support system; undercutting of the trench sides will not be permitted.
Table 2.1 – Maximum pipe trench width at 300mm above pipe crown
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Nominal Bore Maximum Trench Nominal Bore
M Maximum Trench
mm Width mm mm Width mm
100 550 600 1350
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150 600 800 1550
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200 800 1000 2000

300 900 1200 2300
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400 1000 1400 2500

500 1250 1500 2700
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If the Contractor exceeds these trench widths he shall provide plain or reinforced concrete
cradles and /or reinforced concrete arches to the requirements shown on the drawings and to
the approval of the Engineer at no additional cost. When directed by the Engineer, supply
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and install strong and sufficient shoring to support excavations at no additional cost.
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5 No additional payment will be made to the Contractor for working in a confined space or if the
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position of the Works precludes the use of mechanical excavators or the storage of
excavated materials next to the excavations.
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6 The Contractor shall submit shop drawings of all temporary works and trench support
systems or proprietary manufacturers’ catalogues detailing his proposed methods of
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construction at least one month prior to starting excavations. The shop drawings shall be
complete with all details, design calculations, and description of construction methods. The
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Engineer’s approval of the Contractor’s submittal shall not relieve the Contractor from
obligations under the Contract.
7 Except as otherwise precluded by the Project Specification, the Contractor may propose to
excavate with battered side slopes. If required by the Engineer, the Contractor shall provide
three copies of a report which shall include relevant calculations and method statement
demonstrating the adequacy of the proposals.
Part 02: Earthworks
8 In the event of any trench being excavated with battered or stepped sides, that portion of the
trench which extends from the formation to a point not less than 300 mm above the crown of
the pipe when laid in its correct position shall be formed with vertical sides. Support shall be
provided to the vertical trench sides to prevent ground movement. Where temporary trench
supports are provided they shall be such that no ground movement occurs on removal.
9 Where battered sides are proposed, no excavation work shall begin until the Engineer’s
approval has been obtained. The Engineer’s approval shall not relieve the Contractor from
his obligations under the Contract.
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10 The line and level of trenches shall be as shown on the Drawings and shall be maintained in
accordance with the following procedure:
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(a) before beginning trench excavations, the route of the pipeline shall be surveyed and
set out accurately and the existing ground level shall be agreed with the Engineer
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(b) sight rails shall then be fixed and maintained at each change of gradient, and at as
many intermediate points as may be necessary. The centreline and the level to which
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the excavation is to be carried out shall be marked on the site rails and the rails shall
not be more than 20 m apart
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(c) alternate methods to maintain line and level of excavations shall be subject to the
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11 Trench excavation shall be carried out as follows:

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(a) trench excavation shall be carried out by such methods and to such lines, dimensions
and depths as shall allow for the proper construction of the Works
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(b) trench widths shall conform with the limits shown on the Drawings, or ,in the case of
flexible pipes, to the widths stated in the Contractor’s approved methods statement.
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Where trench widths do not conform to the limits shown on the Drawings, the Engineer
will direct the Contractor as to the measures to be taken to remedy the situation. Such
remedial works shall be carried out by the Contractor as an obligation under the
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Contract at no additional cost to the Employer

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(c) rock encountered in trench excavations shall be so excavated that the clearance
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between the pipe, when laid, and the rock sides and bottom of the trench is kept to
the minimum limits necessary to provide for the specified thickness of bedding and
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where provided the concrete protection of the pipe

(d) bell holes and holes and depressions for couplings, valves and the like shall be
excavated the same distance below these installations as specified for the pipe.
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(e) When the trench width measured 300mm above the crown of the pipe exceeds the
maximum allowable shown on the drawings for granular surround the Contractor shall
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proceed as Clause 4.3.2 of this Section.
12 Limitations on the lengths of opened trenches shall be as follows:
(a) no length of trench excavation shall begin until the pipes and fittings to be laid in the
length of excavation are available at the Site.
(b) the Engineer reserves the right to direct the Contractor on the lengths of trench
which shall be excavated at any one time
(c) the Contractor shall not be permitted to excavate trenches in more than one location
in any road at a given time without the Engineer’s approval
Part 02: Earthworks
(d) in areas accessible by the public, the maximum length of open trench in any one
section shall not exceed 100 m. In other areas the trench shall be dug only so far in
advance of pipe laying as the Engineer shall permit.
13 The Contractor shall at his own expense remove from the Site all unsuitable and excess
material resulting from excavations beyond that required for the foundation, lining or bedding
and shall make good the same with concrete or suitable fill material as may be required by
the Engineer.
14 The Engineer will inspect ground condition, or trench formation level and may direct the
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Contractor to remove additional material and to refill the excavation with concrete or other
approved material. Should any acceptable native material at the foundation level
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subsequently become unsuitable the Contractor shall remove it and replace it with concrete
or other suitable material as directed by the Engineer at no additional cost to the Employer.
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15 If utility obstructions are encountered during excavation and cannot be diverted, the
Contractor shall make the necessary changes to the design drawings and submit to the
Engineer for approval. The Contractor shall not make any deviation from the specified lines
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or grade of the tunnel without written approval from the Engineer.
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16 Excavation shall be carried out to the dimensions, depths or levels in such a manner as to
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avoid excavation of or disturbance of material below grade.
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17 Pipes of greater strength or the use of superior pipe bedding may be used in lieu of
maintaining the maximum trench widths shown in Table 2.1 or specified for various pipe
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diameters, subject to the Engineer’s prior written approval.

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18 The Contractor shall excavate trenches to the levels that will allow for the pipe wall thickness
and bedding thickness.
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19 The Contractor shall leave a clear space as approved by the Engineer, between the edge of
the excavation and the inner toes of the spoil banks.
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20 The Contractor shall grade the trench bottom with hand tools, remove loose and disturbed
material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for
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bedding material if shown on the design drawings or as specified.

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21 The Contractor shall remove soft sub-grade that may cause pipe settlement and replace with
suitable backfill compacted in layers not exceeding 150 mm.
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22 The bottom of excavations for permanent structural works shall be free from mud and water,
trimmed clean, protected from the effects of the weather and consolidated to achieve the
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required bearing capacity prior to the placement of structural work or construction materials
within the excavation.
2.2.7 Appurtenant Structures for Pipelines
1 The Contractor shall carry out the necessary excavations to accommodate appurtenant
structures such as manholes, chambers and thrust blocks. The requirements for the
completion of excavations and handling of excavated material shall be as specified above for
trench excavations shall apply.
Part 02: Earthworks
2.2.8 Excavation in Roads
1 In addition to the foregoing and the provisions of Section 1, pipeline excavation in roads and
highway reserves including the provision of public safety facilities including barriers and
enclosures shall be in accordance with the Code of Practice and Specification for Road
Openings in the Highway published by the Highway Maintenance Section, Roads
Department, Ministry of Municipal Affairs and Agriculture (MMAA).
2 Where trenches are excavated open cut in roads, the asphalt shall be saw cut along the
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edges of the trench, prior to excavation.
3 In the lanes of the road that remain open to traffic, road drains and channels shall be kept
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free from construction materials, debris and obstruction at all times.
4 Normally trench excavation along roads shall be located in the service reserves or verges
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adjacent to the road rather than in the carriageway itself. Trench excavation shall wherever
practicable be carried out in such a way that every part of the excavation is at least 1 m clear
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of the existing edge of the carriageway. The Contractor shall obtain information regarding
utilities reservations from the Planning Department of the Ministry of Municipal Affairs &
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Agriculture and refer to their publication entitled Road Hierarchy: General Guidance for Road
Cross-Sections and Utilities Disposition. M
5 The Contractor shall take special precautions, which includes the continuous support of the
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sides of the excavation, from the start of excavation until the refilling and compaction of the
trench backfill material is completed.
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6 The Engineer may direct the trench excavation to be realigned from that shown on the
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Drawings to facilitate the flow of traffic.

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7 Where trench excavation or any other part of the Works obstructs any footpath or right-of-
way, or property access, the Contractor shall provide, at his own cost, a temporary access
around the obstruction to the satisfaction of the Engineer. Where applicable, this temporary
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access shall include stout wooden bridges with hand rails and kick boards or other approved
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construction across any open trench. Suitable steel road plates shall be provided and
maintained where vehicle access is deemed necessary.
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8 No excavated material shall be permitted to be deposited or stockpiled in grassed or planted

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areas. The Contractor shall immediately remove excavated material to a temporary storage
area and import selected approved materials for the trench filling operations.
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9 Where excavated material has temporarily been deposited on a verge, the verge shall on
completion of backfill be restored to its original condition and left free from debris.
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2.2.9 Excavation in Areas Other Than Road Reserves
1 Areas other than road reserves shall include but not be limited to cultivated areas,
undeveloped areas, footpaths, verges, non-asphalt roads, lanes, alleys, and all private lands.
2 The Contractor shall take measures to prevent access of unauthorised persons, the general
public and animals to areas in which there are open excavations, access routes and steep or
loose slopes arising from the Contractor’s operations.
Part 02: Earthworks
3 The Contractor shall provide adequate temporary barriers and fencing. When necessary,
barriers and fencing shall be illuminated.
4 Temporary barriers and fencing shall not be removed without the Engineer’s written
permission, which will not normally be given until the trench excavation has been refilled and
reinstated.
2.2.10 Support of Excavations
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1 The Engineer reserves the right to direct the Contractor to take measures to augment the
Contractor’s proposals for the support of excavated surfaces. If, in the opinion of the
Engineer, the support proposed by the Contractor is insufficient, the Contractor shall modify
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his proposals and provide trench support as directed by the Engineer. The absence of the
Engineer’s direction, or action by the Contractor in accordance with the direction of the
Engineer shall not relieve the Contractor of his obligations under the Contract.
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2 Shoring shall be properly maintained until in the opinion of the Engineer the permanent work
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is sufficiently advanced to permit the shoring to be removed. The removal of shoring shall be
carried out only under the personal supervision of a competent foreman. If the Contractor
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proposes not to remove the shoring on completion of the permanent work he shall obtain the
Engineer’s prior written approval. M
3 All temporary works supporting the faces of excavations shall be removed during backfilling
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with the approval of the Engineer. Where removal is impracticable and with the approval of
the Engineer, temporary works shall be left in place. Temporary works left in place shall be at
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no additional cost to the Employer.

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4 When, in the opinion of the Engineer, temporary supports need to be left in excavations to
support existing structures or the permanent Works, the Engineer may direct that temporary
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supports be left in place. Temporary supports left in place shall be at no additional cost to the
Employer.
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5 Underpinning, supports and other protective measures that are required for buildings,
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structures and apparatus in or adjoining excavations shall be provided by the Contractor.

Such permanent or temporary works shall be of adequate design and construction. When
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directed by the Engineer, the Contractor shall submit his methods statement for such work
for the approval of the Engineer. The Engineer’s approval shall not relieve the Contractor
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from his obligations under the Contract.

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6 Damage to the Works and any consequential damages caused by the removal of shoring are
the responsibility of the Contractor. Permission or approval by the Engineer to remove
shoring shall not relieve the Contractor from this responsibility.
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2.2.11 Slips and Falls and Excess Excavation
1 Slips and falls in trenches shall be prevented as follows:
(a) the Contractor shall effectively support the sides of all trench excavation to prevent
slips and falls of material in the excavation. Support may include the use of closed
sheeting or steel sheet piles, where necessary, to prevent any fall or run from any
portion of the ground outside the excavation into the trench and to prevent settlement
of or damage to existing services and structures next to the excavation
Part 02: Earthworks
(b) any excavation carried out by the Contractor to prevent slips and fall, or should
portions of trench walls slip or fall away, the Contractor shall at his own expense take
all necessary remedial measures including the excavation removal and reinstatement
of all the ground thereby disturbed
(c) in all cases where the voids so formed when backfilled would provide support for the
permanent Works or adjacent structures and services, such voids shall be filled
with Grade 20 SRC concrete at the Contractor’s expense. In all other cases the voids
shall be filled with selected excavated material compacted as specified in this Part.
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2.2.12 Trimming and Levelling
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1 No excavation shall be filled in or covered with concrete until it has been inspected by the
Engineer.
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2 Where shown on the Drawings or instructed by the Engineer, a layer of blinding concrete
shall be placed to the required thickness to protect the formation and provide a clean working
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surface.
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3 The Contractor shall compact the formation before placing the blinding concrete, when in the
opinion of the Engineer the formation density can be improved by compaction.
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4 When excavating to specified levels for trench excavation for pipelines, or to specified limits
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for the face of any thrust block or other structure required to abut or to rest upon undisturbed
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ground, excavations shall be trimmed as follows:
(a) the Contractor shall not excavate the last 150 mm until immediately before beginning
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construction work except where the Engineer permits otherwise. Should the
Contractor have excavated to within 150 mm above these specified levels or to within
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150 mm of these specified limits before he is ready or able to commence the

construction work he shall where required by the Engineer excavate further so as to
remove not less than 150 mm of material immediately before commencing the
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construction work and any such further excavation and additional foundation material
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ordered by the Engineer shall be at the cost of the Contractor. The last 150 mm shall
be hand excavated
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(b) the bottom of excavations shall be carefully boned in and trimmed true to grade with
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the aid of a straight-edge.

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2.2.13 Excavations Not to be Left Open
1 Trench excavation shall be carried out expeditiously in the following manner:

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(a) the refilling and surface reinstatement of trench excavations shall begin and be
completed as soon as reasonably practicable after the pipes have been laid and
jointed
(b) the Contractor shall take precautions to prevent flotation of pipes in locations where
open trench excavations become flooded, and these precautions shall include the
partial refilling of the trench leaving pipe joints exposed for tests of the joints
Part 02: Earthworks
(c) if the Engineer considers that the Contractor is not complying with the foregoing
requirements, The Engineer will not permit further trench excavation until he is
satisfied with the progress of laying and testing of pipes and refilling of trench
excavation.
2.2.14 Dewatering of Excavations
1 For construction dewatering refer to Section 1 Part 24 Construction Dewatering.
2 The Contractor shall submit methods statements including drawings and data showing the
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intended plan for dewatering operations. Details of locations and capacities of dewatering
wells, well points, pumps, sumps, collection and discharge lines, standby units, water
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disposal methods, monitoring and settlement shall be included. The methods statement shall
be submitted to the Engineer for approval not less than 30 days before the start of
dewatering operations. The Engineer reserves the right to reject the proposal if he is not
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satisfied with measures.
3 The Contractor shall satisfy himself on the scope of dewatering necessary for the
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construction of the Works and shall make the necessary investigations to obtain the required
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data and information.
4
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Where necessary, the Contractor shall divert natural and artificial waterways encountered at
the Site until the Works are completed.
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5 The Contractor shall perform dewatering as necessary to ensure that

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(a) the Works are installed on dry areas and excavations, including without limitation the
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construction of all structures and underground piping

(b) dewatering is carried out only to a depth sufficient for the required excavation
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(c) during construction, no groundwater shall come into contact with any concrete surface
or reinforcement
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(d) structures shall be capable of withstanding any hydrostatic pressure to which it may
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be subjected during construction and until completed.

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6 The Contractor’s dewatering operations shall be conducted so as not to endanger the

foundations or stability of the Works or any adjacent structures. Damage caused by the
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Contractor’s operations shall be made good by the Contractor at no additional cost to the
Employer.
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7 Discharge of groundwater from excavations to the sea, into surface storage ponds or deep
well recharge shall require the approval of the Ministry of Environment.
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8 Water removed from excavations shall first pass through settlement tanks and on-site
treatment prior to discharge.
9 Unless otherwise approved by the Engineer, wellpoint dewatering systems shall be provided
on both sides of trenches.
Part 02: Earthworks
10 The static water level shall be drawn down a minimum of 300 mm below the bottom of the
excavation so as to maintain the undisturbed state of the foundation soils and allow the
placement of any fill or backfill to the required density. The dewatering system shall be
installed and operated so that the groundwater level outside the excavation is not reduced to
the extent that would damage or endanger adjacent structures or property.
11 The Contractor shall, where extensive dewatering is required, be fully qualified to perform the
dewatering operations or shall furnish the services of an experienced, qualified, and
equipped dewatering subcontractor to design and operate the dewatering and groundwater
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recharging system required for the work, all subject to the Engineer’s approval.
12 When directed by the Engineer, the Contractor shall establish a specified number of
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groundwater level monitoring stations at each site which shall be observed during the work.
These shall be located as directed by the Engineer and consist of acceptable open tube
piezometers. When directed by the Engineer, the Contractor shall provide settlement gauges
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to the approval of the Engineer and monitor settlement of new and existing facilities.
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13 Dewatering shall not result in the flow of water along the pipe zone material. Full
consideration should be given to the use of cut-off walls to reduce the potential for
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groundwater flow along pipe trenches. The Contractor shall submit for the Engineer’s
approval, details of his proposed method of working and temporary works installations to
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achieve this.
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14 If the use of drainage conduits, channels or subdrains is approved by the Engineer and are to
be left in place below the level and within the width limits of permanent Works they shall be
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structural capable of providing support. Ballast filled subdrains to be left in place under
concrete shall be covered with a geotextile membrane. Subdrains left in place shall be filled
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with Grade 20 SRC concrete or an approved cementitious grout.

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15 The release of groundwater to its natural static level shall be performed so as to maintain the
undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or
backfill and prevent floatation or movement of structures, pipelines and sewers.
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16 No dewatering system shall be removed until infiltration testing is completed nor without the
approval of the Engineer. Monitoring and settlement measurement systems shall be
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maintained in operation until removal is approved by the Engineer. With the approval of the
Engineer, wellpoints and like items may be abandoned in place.
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17 Partially completed permanent works shall not be allowed to become flooded and the
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Contractor shall allow for additional standby pumps and equipment required to ensure this. A
pump operator shall be on site 24 hours per day to supervise pumping equipment.
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18 In the event of partially completed trenches becoming flooded, the Contractor shall re-
excavate to formation level and re-lay the pipes.
19 The Contractor shall provide a silt-trap in any temporary drain which he may construct and
prior to discharge into any permanent drain which he may wish to use for the removal of
water during the construction period. The Contractor shall keep both temporary and
permanent drains clear of silt to the satisfaction of the Engineer until the completion of the
Contract. Any silting up of the watercourses arising from the Contractor’s failure to comply
with this Clause shall be remedied at his expense whether within the Site or not.
2.3 BACKFILL
Part 02: Earthworks
2.3.1 Pipe Bedding
1 Pipe bedding shall be provided as shown on the Drawings or stated in the Contractor’s
approved methods statement.
2 Pipe bedding shall be well compacted to a minimum void ratio to provide a high load-bearing
capacity and a stable base below the pipe and shall completely fill the whole width of the
trench excavated. Compaction requirements equivalent to at least 90 percent of the Standard
Proctor Maximum Dry Density shall be achieved. Additional bedding necessary to fill voids
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created by over excavation shall be provided entirely at the Contractor’s expense.
3 Pipe bedding shall consist of granular material and shall shall conform with the following
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requirements:
(a) shall be free of organic and deleterious matter and shall consist of strong durable
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crushed un-weathered rock or stones having roughly cubical or pyramidal shaped
fragments, graded and tested from a source approved by the Engineer. No reactive
carbonate rock or sources with indication of local groundwater contamination shall be
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used.
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(b) pipe bedding material for rigid pipes shall be according to the following grading limits
giving in Table 2.2.
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Table 2.2 – Gradation Requirements for Pipe Bedding, Rigid Pipes
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<300 300 - 800 >800

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Sieve Size % by Mass % by Mass % by Mass

Passing Passing Passing
25mm - - 100
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20mm - 100 90 - 100

14mm 90 - 100 80 - 100 50 – 80
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10mm 50 - 85 60 - 85 40 – 70
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5mm 10 - 40 20 - 55 25 – 60
2.36mm 0 - 10 10 - 30 10 – 40
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0.300 - 0 - 10 0 - 15
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(c) The minimum thickness of pipe bedding material below the barrel of the pipe is given
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in Table 2.3.
Table 2.3 – Minimum thickness of bedding material below barrel of pipe
Uniform Soil
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Nominal Bore
Hand Finished Machine Dug Rock
(mm)
Trench Bottom Trench Bottom
100 & 150 100 150 200
200 - 500 150 200 250
600 - 800 175 225 275
1000 & above 200 250 300
(d) Pipe bedding and backfill to French drains shall be in accordance with Section 6, Part
14, Clause 14.9.5.
Part 02: Earthworks
(e) The total loss factor for the granular material used in French drains using the ten
minute rotational test shall not exceed 10%.
(f) Chloride and sulphate levels for bedding materials shall conform to BS EN 10319.
4 Pipe bedding material for flexible pipes be accoding to the following grading limits given in
Table 2.4.
Table 2.4 – Gradation Requirements for Pipe Bedding, Flexible Pipes
Pipe Diameter (mm)
Sieve Size <300 ≥300
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% by Mass Passing % by Mass Passing
14mm - 90 - 100
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10mm 50 - 85 50 - 85
5mm 10 - 40 0 - 10
2.36mm 0 - 10 0 - 10
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The minimum thickness of granular bedding material around the barrel of the pipes shall be
100mm. Should the Contractor exceed the trench widths given in Table 2.1 he shall precede
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as Clause 4.3.2 of this Section.
5
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The design of GRP and PE pipes and bedding is specified in Parts 3 and 4 of this Section.
Granular bedding materials for GRP pipe shall be 10mm nominal size according to the
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grading limits given in Table 2.4 and also meet the manufacturer’s requirements.
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6 After trimming and compaction of the formation, granular bedding material shall be spread in
the trench bottom.
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7 Cut-off walls shall be formed in granular bedding and surround to pipes to prevent the
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bedding acting as a subsoil drain. Cut-off walls shall be provided at a maximum spacing of
40 m with one at each manhole and structure and at least one cut-off wall between two
adjacent manholes and structures.
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8 Cut-off walls shall be made from an impervious fine grained clay mixture, prepared with
addition of water where necessary, to suitable trench spoil if available, or imported. Concrete
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cut-off walls shall be Grade 20 SRC concrete. Cut-off walls shall be installed across the full
cross-section of the granular bedding material and shall be at least 300 mm wide along the
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axis of the pipeline.

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9 Concreting to the pipeline shall be either bed or bed and surround or encasement or backfill
as shown on the Drawings or directed by the Engineer and shall be of Grade 20 SRC
concrete placed as follows:
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(a) concrete shall not be placed until the joints at each end of the pipe have been
completed
(b) each pipe to be encased shall be supported on at least two purpose made precast
concrete blocks, which shall be left in place
(c) concrete encasement shall be placed to the required depth in one operation and pipes
shall be prevented from floating or otherwise moving during concreting
(d) continuity of concrete backfill or encasement to pipe with flexible joints shall be
broken at each joint, unless otherwise approved by the Engineer
Part 02: Earthworks
(e) flexible joints in concrete beds and surrounds to pipes shall be formed as shown on
the Drawings with suitable compressible fibrous board or other similar approved
material
(f) compaction shall be carried out with approved mechanical vibrators. The maximum
period of time between mixing of the materials and final compaction of any given
material shall be kept to a minimum.
10 Where unstable ground conditions are met which are likely to cause undue settlement in the
pipeline, the Contractor shall submit a report including site data and the Contractor’s proposal
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for remedial works including structural calculations for the approval of the Engineer. The
Contractor shall carry out the following remedial works as directed by the Engineer.
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(a) improvement of mechanical properties of the soil
(b) replacement of soil by other soil or blinding concrete
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(c) pile foundations
(d) reinforced concrete slab foundation.
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2.3.2 Pipe Surround
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1 Pipe surround shall be provided as shown on the Drawings or stated in the Contractor’s
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approved method statements.
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2 When concrete cradles are used, all concrete shall have attained adequate strength before
backfilling of the excavation commences between the completed structure and sides of
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excavations.
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3 Material for pipe surround and to the first 300mm above the top of the pipe, shall be granular
material as specified in Clause 2.3.1. The material shall be free from sharped edged stones
or other material which may cause damage to the permanent Works.
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4 Material for pipe surround shall be placed in layers of not greater than 150mm compacted
thickness and thoroughly rammed with suitably shaped rammers working alternatively on
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either side of the pipe until the fill has been carried up at least 300mm above the top of the
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pipe. Care shall be taken to avoid damage to the pipe, coating or sheathing.
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5 Compaction requirements equivavlent to at least 90 percent of the Standard Proctor

Maximum Dry Density shall be achieved.
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2.3.3 Geotextile Filter Membrane

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1 Geotextile filter membrane for surround to granular material for ground water drainage shall
conform with the requirements of Section 6 Part 15 Clause 15.1 and shall be used in the
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zone extending downwards from 1.5m above the long term water table. The long term water
table is to be determined on the basis of observations made on site of the initially
encountered water table in the excavations. The placement of Geotextile is then to be
directed by the Engineer. Geotextile membrane for structural support to pipe surround in soft
ground shall be wrapped round the granular bedding as shown on the Contract drawings.
2 For both of the above applications the geotextile properties shall be:
(a) mean peak strength BS EN ISO 10319 8kN/m

(b) elongation at peak strength BS EN ISO 10319 28%
(c) CBR puncture resistance EN ISO 12236 1500N
Part 02: Earthworks
(d) pore size (O90) EN ISO 12956 0.15mm

2
(e) permeability (50cm head) EN ISO 11058 100l/m .s
3 The fabric shall be woven or non-woven consisting of long chain polymeric filaments or yarns
formed into a stable network such that the filaments or yarns retain their relative position to
each other.
4 The fabric shall be inert to commonly encountered chemicals and chemical properties of the
soil and water. Geotextile fabric shall surround the granular bedding as follows:
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(a) the surface to receive the fabric shall be formed to a relatively smooth condition free
of obstruction, depressions, and debris. The geotextile fabric shall be laid loosely.
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(b) if the proposed area for fabric requires more than one panel width of fabric, the
panels shall be overlapped a minimum of 15 percent of the panel width
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(c) to prevent slippage of the overlapping fabric, the areas of overlap shall be stabilised,
as approved by the Engineer, with pins, anchor blocks, or piles of aggregate
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(d) fabric damaged or displaced before or during installation or during placement of
backfill material shall be repaired or replaced
2.3.4 Backfilling Excavation

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1 All concrete shall have attained adequate strength before backfilling of the excavation
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commences between the completed structure and sides of excavations.
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2 Selected fill material for trench backfill in open areas, shall be suitable material selected from
the excavated material as specified in Clause 2.2 of this Part. Stones larger than 150 mm in
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size may be allowed, provided in the opinion of the Engineer, the required densities can be
achieved.
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3 Selected fill material for trench backfill under paved areas, shall be suitable material selected
from excavated materials meeting the following requirements:
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(a) maximum stone size of 75m

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(b) the material passing the 0.063 sieve shall be less than 15%
(c) the liquid limit shall not exceed 35% and the plasticity index shall not exceed 6%
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(d) the uniformity coefficient shall not be less than 10

(e) the total water soluble / acid soluble salt content (for sulphate and chloride) shall not
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exceed 2%
(f) organic content shall not exceed 2%
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(g) the CBR value shall not be less that 15% at 95% maximum dry density at the formation
level. The test procedure shall be as Section 6, Clause 3.10 of the specification.
4 The trench backfill material shall be placed in layers of not greater depth than 200mm
thickness and be thoroughly compacted to 95 percent of the Standard Proctor Maximum Dry
Density by approved mechanical compaction equipment. In roads and footpaths, the coarse
filling is to be carried up to the level at which surface reinstatement is to begin; elsewhere, to
such level as with the surface reinstatement of the whole of the topsoil will leave the finished
work sufficient to allow for future settlement to the original ground level.
Part 02: Earthworks
5 The moisture content of the material before compaction shall not vary by more than ±2% of
the optimum moisture content (BS 1377 Part 2:1990, Test 3.2). If in the opinion of the
Engineer, the fill is too dry, it shall be watered at the expense of the Contractor in an
approved manner during refilling as may be directed by the Engineer.
6 Any nuclear density measurement (NDM) tests undertaken shall be performed only by
persons or companies holding a valid Authorised User Certificate issued by the Materials
Central Laboratory. Each NDM device shall have a valid Calibration Certificate, also issued
by the Central Materials Laboratory.
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7 The Contractor shall provide the necessary testing apparatus for monitoring soil properties
and shall maintain the apparatus in good working order. A daily log of tests carried out shall
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be provided to the Engineer. Testing of soil properties shall be carried out by an approval
laboratory.
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8 Tests to determine the optimum dry density of the fill material shall be carried out as directed
on site, the frequency depending on consistency of material and test results.
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9 Unless directed otherwise, testing for density and moisture content shall be at the rate of:
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(a) one test per backfill layer for each structure such as manholes, chambers, and thrust
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blocks
(b) one test per backfill layer for every 30 m of pipeline trench.
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10 Should the backfilling material being placed become unacceptable to the Engineer due to
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(a) exposure to weather

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(b) flooding
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(c) having become puddled, soft, segregated

(d) otherwise unacceptable during the progress of work
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the Contractor shall at his own expense remove such damaged, softened or
segregated material and replace it with fresh approved material.
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11 To permit the proper consolidation of backfill into the voids behind trench sheeting and
supports, trench sheeting shall be withdrawn gradually as backfill progresses in depth and
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along the trench.
12 On no account shall any excavated material be dozed back when filling trenches in roads and
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no filling shall be carried out unless in the opinion of the Engineer, sufficient mechanical
compactors are in operation on that portion of the work.
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13 Where in the opinion of the Engineer sufficient supplies of the suitable material for trench
backfilling cannot reasonably be obtained from excavations the Engineer may order the
Contractor to:
(a) carry out such work as may be necessary to screen out stones
(b) borrow excavate material from suitable borrow areas on the Site or off the Site and
transport it to the length of trench to be filled to the approval of the Engineer.
All costs for borrow material shall be borne by the Contractor.
Part 02: Earthworks
14 Trench backfilling shall be carried out expeditiously as soon as practicable after the pipeline
has been laid, tested and approved.
15 Trench bottom shall be free of any foreign material or backfill contaminated with foreign
material from the trench bottom.
16 Check grade and correct irregularities in bedding material. Loosen top 25-50 mm of
compacted bedding material with a rake or by other means to provide a cushion before laying
each section of pipe, conduit, direct-buried cable, or duct bank.
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17 Place backfill material simultaneously in lifts on both sides of pipe and, if applicable, between
pipes, conduit, cables, and duct banks installed in the same trench.
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(a) Pipes up to and including 250 mm in diameter: First lift of backfill less than or equal to
1/2 pipe diameter.
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(b) Pipe over 250 mm in diameter: Maximum 150 mm lifts.
18 Thoroughly tamp each lift, including the area under haunches, with handheld tamping bars
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supplemented by “walking in” and slicing material under haunches with a shovel to ensure
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that voids are completely filled before placing each succeeding lift.
19
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After the full depth of the pipe zone material has been placed as specified, compact the
material by a minimum of three passes with a vibratory plate compactor only over the area
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between the sides of the pipe and the trench walls.
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20 Do not use power-driven impact compactors to compact pipe zone material.

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21 Backfill used above pipe zone shall be processed to meet specified gradation requirements.
Adjust moisture content as necessary to obtain specified compaction.
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22 Do not allow backfill to free fall into the trench or allow heavy, sharp pieces of material to be
placed as backfill until after at least 600 mm of backfill has been provided over the top of the
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pipe.
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23 Do not use power driven impact type compactors for compaction until at least 1.2 m of
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backfill is placed over top of pipe.

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2.3.5 Backfilling Excavations with Cement-Bound Granular Material
1 Backfilling excavations with cement-bound granular material shall be used for filling
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excavations at manholes, access shafts, pipe line structures in roadways, underneath

exposed existing pipelines or as approved by the Engineer.
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2 Cement-bound granular material shall consist of crushed, hard, clean, durable rock or
washed sand or a combination thereof. The material shall be sufficiently well-graded to
ensure a well-closed surface finish and have a grading within the range shown in Table 2.4
Table 2.4 – Grading for cement-bound granular material
BS 410 sieve size Percentage by Mass Passing

50 mm 100
37.5 mm 95 - 100
20 mm 45 - 100
Part 02: Earthworks
10 mm 35 - 100
5 mm 25 - 100
600 m 8 - 65
300 m 5 - 40
75 m 0 - 10
3 The granular material shall be mixed with sufficient cement to provide the crushing strength
specified in Paragraph 12 of this Clause. The material shall be mixed in a paddle or pan type
mixer which may be batch or continuous type. Where a batch mixer is used, the mixing times
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shall not be less than one minute unless the Engineer approves a shorter time subject to the
results of preliminary trials. Where a continuous mixer is used, the paddles, baffles and rate
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of feed of materials shall be adjusted to provide a uniformly mixed material. Where a spray
is used for distributing water into the mixer, it shall be adjusted to provide a uniform moisture
content throughout the mix.
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4 The moisture content of the mixed material shall not exceed 2 % above the optimum as
determined in accordance with the Vibrating Hammer Test of BS 1924.
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5 The Contractor shall carry out preliminary tests on trial mixes to attain the specified crushing
strength. M
6 Plant-mixed material shall be transported to the site by vehicles which shall have capacities
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suited to the output of the mixing plant and site conditions, and be capable of clean
discharge. Mixed material shall be immediately transported to its required location and shall
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be suitably protected from the prevailing climatic conditions during transportation and the
period before tipping.
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7 All mixed material shall be placed and immediately spread evenly in one layer such that after
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compaction the thickness does not exceed 150 mm.
8 Compaction in trenches shall be carried out immediately after the material has been spread
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and completed within two hours of the addition of cement.

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9 Compaction shall be carried out to achieve a density equivalent to 95 % of the average

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density of the set of five cubes required for testing in paragraph 12 of this Clause.
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10 Any layer of cement-bound granular material not covered within two hours shall, immediately
on completion, be cured for a minimum period of 7 day unless otherwise approved by the
Engineer or the surface is covered by permanent works. Surface curing shall be achieved by
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covering with impermeable plastic sheeting until the next permanent layer is laid. The plastic
sheeting shall be adequately secured to the surface and joints shall be have a minimum
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300 mm overlap, set to prevent egress of moisture.

Part 02: Earthworks
11 Samples of the mixed material shall be taken from the site immediately before compaction of
the material. A batch of five random samples shall be taken from each layer or such other
area as decided by the Engineer. From each sample a cube test specimen shall be
prepared, cured and tested using the procedure in BS 1924. The specimens shall be
compacted to be within 95 % of the cube density when compacted by vibratory hammer. The
specimens shall then be cured at constant moisture content within the range of curing
temperatures stated in BS 1924 for a period of 7 days. The specimen shall then be weighed,
the dimensions checked and tested in unconfined compression. A representative portion of
the crushed material from each specimen shall then be retained for a moisture content
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determination in accordance with BS 1924 and the dry density of each specimen determined
using mass, dimensions and the moisture content of the material.
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12 The average 7 days crushing strength for each batch of five test specimens made and tested
in accordance with the method described herein shall be not less than 3.5 MPa for cubes. In
addition to complying with the minimum strength requirements, the root mean square of the
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coefficient of variation of the crushing strength of five successive batches of five test
specimens of the cement-bound granular material shall not exceed 25 %. If an area or layer
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of cement-bound granular material represented by these specimens fails these tests, the
defective material shall be removed and replaced with new material at the Contractor’s
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expense.
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13 The cement-bound granular material shall in no case be less than 150 mm thick from the
outside barrel of the pipe to the nearest point of the shoring, and the greatest care shall be
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exercised to ensure complete filling of all voids and thorough consolidation of the concrete.
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The Contractor shall allow in his prices for the additional concrete used in excess of the net
requirement.
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14 Cement – Bound Granular Material discharged from truck mounted drum type mixer into
trench shall:
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(a) Placed in lifts as necessary to prevent uplift (flotation) of new and existing facilities.
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(b) In travelled areas, fill entire trench section to pavement finish grade for a temporary
driving surface, and screed off excess and finish with a float.
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(c) In other areas, fill the trench section as shown on the Contract Drawings.
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2.3.6 Backfilling Excavation with Flowable Fill (Foamed Concrete)

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1 Backfilling excavations with flowable fill shall be used for filling excavations at manholes,
trenches, access shafts, pipeline structures in roadways, underneath exposed existing
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pipelines or as approved by the Engineer.

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2 Flowable fill may be placed by chutes, conveyors, buckets or pumps depending upon the
application and accessibility.
3 For trench backfill, flowable fill shall be placed continuously. To contain the flowable fill along
long open trenches or open ended structures in stages, the end points shall be adequately
bulkheaded to prevent movement.
4 Flowable fill shall be placed in a manner to prevent flotation or displacement of the

embedded item.
Part 02: Earthworks
5 The 28-day compressive strength of the flowable fill shall be 5 MPa with a unit density of
3
between 1600 – 2000 kg/m . Accelerators may be used subject to the approval of the
Engineer.
2.3.7 Backfilling Next to Pipeline Structures
1 Fill materials adjacent to structures such as manholes and chambers shall be placed in
accordance with Clause 2.3.4 above.
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2 Fill material next to structures other than pipeline structures shall be carried out as Specified
in Section 12.
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2.3.8 No-Fines Concrete as Trench Backfill
1 Except where otherwise noted in this Clause, the design, manufacture, use and testing of no-
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fines concrete shall comply with the requirements of Section 5 Part 6.
2 All material shall be placed and spread evenly. The full width of the excavated trench shall be
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filled; formwork other than that required for temporary constructions joints will not be
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permitted. The Contractor shall be responsible for the use of any extra material required to fill
the trench beyond the maximum trench widths detailed on the drawings. The no-fines
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concrete shall generally be brought up to a height no higher than the level of undisturbed rock
on either side of the trench.
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3 Compaction shall be carried out with approved mechanical vibrators. The maximum period of
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time between mixing of the materials and final compaction of any given material shall be kept
to a minimum.
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4 Any layer not covered within 2 hours by another layer of no-fines concrete shall, immediately
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on completion of compaction, be cured for a period which shall not be less than 7 days
unless the Engineer agrees otherwise. Curing shall be achieved by covering until the next
layer is laid with impermeable plastic sheeting, adequately secured from being blown off the
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surface and with joints overlapped at least 300mm and set to prohibit egress of moisture.
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2.4 REINSTATEMENT OF SURFACES

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ER
2.4.1 Reinstatement within the Highway
1 All reinstatement of roadworks to be carried out in the public highway shall be carried out in
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accordance with the latest “Code of Practice and Specification of Road Openings in the
Highways”.
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2.4.2 Reinstatement of Surfaces Other Than in the Highway
1 Unless provided in the Project Specification, surfaces shall be restored to a condition

conforming to the requirements for the particular surface described in the relevant section of
this Specification. Where no specification exists, restoration shall be to the satisfaction of the
Engineer.
2 All surfaces, gardens or lawns shall be restored to a condition equal to the original surface to
the satisfaction of all Authority requirements, the Engineer and the owners/occupiers.
Part 02: Earthworks
3 Any reinstatement shall be fully maintained by the Contractor until such time that a Taking-
Over Certificate has been issued for the Works or for the Part of the Works containing the
reinstatement.
2.5 EXISTING SERVICES
1 The requirements of this Subpart are in addition to the general requirements specified in
Clause 2.1.5 of this Part.
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2 The Contractor shall be required to submit in advance to the various Utilities Services
Departments and to the relevant Municipality where the Works affect the trees and plants
and a weekly programme of the pipelines he intends to lay in order that the various
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departments can expose or advise on the location of their respective services.
3 Except as otherwise designated in the Project Specification, the Contractor shall be
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responsible for maintaining all services and utilities including but not limited to waterways,
sewers, drains, gas and oil mains, water mains electricity and telecommunication cables and
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all other services, structures, trees, and plants encountered during the construction of the
Works and for any remedial measures necessary to make good any damage caused thereto.
4
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Where designated in the Project Specification, work on services shall be carried out by the
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relevant Utility Service Department. The Contractor shall co-ordinate his work with the work
of the Utility Service Department, and carry out his work so as not to interfere with or damage
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their services.
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5 Where work is carried out close to or across the line of existing services, the Contractor shall
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where necessary provide temporary supports or slings. Where service is interfered with or
damaged, the Contractor shall immediately notify the relevant Utilities Service Department
and shall not undertake repairs without their authorisation and approval. Unless otherwise
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authorised and approved, repairs shall be undertaken by the Utilities Service Department and
the cost of such work shall be borne by the Contractor, and the Contractor shall reimburse
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the Utilities Service Department its account for performing such work.
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6 Where specified on the Drawings or by the relevant Utility Service Departments split ducts,
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conforming with the requirements of Clause 2.7.1 of this Part shall be provided for the
permanent support and protection of services.
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7 The Utility Service Department and the Engineer shall determine whether or not a service
requires to be permanently diverted, temporarily diverted or supported.
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8 Where existing services have to be permanently or temporarily diverted as the unavoidable

result of the construction of the Works, such diversions shall be carried out either by the
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Contractor or the Utilities Service Department as directed by Engineer.
9 Safety shall always be maintained in all work in the vicinity of existing services in accordance
with particular requirements of Utilities Service Department and the requirements of Section
1 and Part 1 of this Section.
10 In addition to the provisions of the above paragraphs, when carrying out pipelaying
operations in the vicinity of existing gas or oil pipelines, the following requirements shall
apply:
Part 02: Earthworks
(a) the minimum clearance between the bottom of the oil or gas line and the top of the
pipeline being constructed is to be 600 mm
(b) a hand excavated pilot hole shall be dug to determine the gas or oil line invert level
and position prior to any trench excavation in gas or oil pipeline reservation
(c) the excavation for the pipeline under construction must be carried out by hand up to
(d) 2.0 m either side of the existing gas or oil pipeline
(e) manually operated jack hammers may be used within 5.0 m of the buried pipeline
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only after completion of item (c) above
(f) the use of mechanical or hydraulic rock-breakers shall not be allowed within 5.0 m of
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the buried pipeline
(g) before the exposure of live pipeline the Contractor is to erect a suitable substantial
barrier to prevent damage to the exposed pipeline.
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(h) on completion of the concrete surround to the pipelines under construction, the
existing gas or oil pipeline shall be rebedded with a minimum of 150 mm of naturally
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occurring soft dune sand bed and surround. The remaining backfill and bund shall be
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made up of selected desert fill with a particle size not exceeding 150 mm which shall
be free from organic matter. The Qatar Petroleum (QP) (onshore) Engineer shall be
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notified a minimum of 24 h in advance, to witness the backfilling operation
(i) damage to the external protective wrapping to the gas or oil pipeline shall be reported
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promptly to the QP who will arrange for the damage to be inspected and repaired
in strict accordance with QP (onshore) procedures at the Contractor’s cost
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(j) the Contractor is to provide constant competent supervision whilst work is carried out
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next to the existing gas or oil pipelines

(k) when the works reach 15 m from the existing gas or oil pipeline, the Contractor shall
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contact the QP (onshore) Engineering Superintendent, who will arrange the necessary
permit to work. QP (onshore) will require a minimum of 48 h notice before work begins
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(l) a QP (onshore) permit to work does not in any way make QP (onshore)
responsible for any of the Contractor’s work, nor does it absolve the Contractor from
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his responsibilities for complying with the above, but only allows the Works to be
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carried out in accordance with the agreed working methods and practices. QP
(onshore) reserve the right to visit the site regularly to observe that the agreed
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methods and practices are being adhered to and to stop the work and withdraw the
permits to work should they consider there is adequate justification to do so
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(m) the requirements of QP (onshore) may vary from and are not necessarily limited
to the foregoing.
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2.6 BLASTING
1 The Contractor shall not use any explosives in the construction of the works without the prior
written approval of the Engineer and such approval shall be contingent upon the Contractor
being authorised by the Civil Defence Department and the Police.
Part 02: Earthworks
2 The Contractor shall inform the Engineer in advance about the types and quantities of
explosives needed. Explosives shall be obtained and used in accordance with the regulations
and procedures of the relevant Government Department. The Contractor shall be deemed to
have copies of relevant documentation and to be knowledgeable of relevant practices. The
Contractor shall provide copies of relevant documentation to the Engineer for the Engineer’s
inspection.
3 Notwithstanding the requirements of this Clause, the Contractor is responsible for the safe
and correct transport, handling and use of explosives.
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4 Except as otherwise provided in the relevant regulations and procedures the handling of
explosives shall be carried out to conform with the requirements stated in the following
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paragraphs.
5 Except as otherwise permitted by the Government, all unused explosives, or explosive
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accessories shall be destroyed at the end of each day’s work.
6 Explosives and detonators shall be carried in separate vehicles during transport. The
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vehicles must be clean and in a good state of repair and be of sufficient capacity to convey
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the explosives safely. The Police may refuse to issue explosives if vehicles do not meet
those standards. A red flag must be clearly displayed by all vehicles when carrying
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explosives.
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7 The Contractor must appoint in writing at least one shotfirer who is in possession of a Qatar
Shotfirer’s Certificate of Competence to carry out all work with explosives on behalf of the
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Contractor. The Contractor shall present and provide copies of such certification to the
Engineer for inspection.
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8 The Contractor must establish simple safety rules covering the handling and use of
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explosives. A copy of these rules will be given to the concerned shotfirer, who will sign a
receipt book kept for this purpose by the Contractor.
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9 The safety rules shall specify:

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(a) the places where explosives are to be used

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(b) times of blasting

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(c) measures to be taken to contain the products of blasting

(d) method of initiation
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(e) posting of warning notices, yellow blasting flags and sentries; and audible warning, if
applicable
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(f) actions to be taken in the event of any unusual occurrence or accident

(g) any other safety aspects relating to the use of explosives
(h) any special instructions concerning transport
(i) instructions relating to the limitation of blast vibrations, where appropriate.
10 The Contractor shall submit a copy of the safety rules to the Engineer.
Part 02: Earthworks
11 Shotfirers shall be responsible to the Contractor for ensuring that all explosives and
accessories are safely and carefully handled and used, in accordance with the regulations
and procedures of the Government, and his own knowledge of correct shotfiring procedure.
12 Where so directed by the Engineer, the Contractor shall provide and operate suitable
instruments to monitor and record the blast vibrations at no additional cost to the Employer.
13 Where blasting vibration could cause nuisance; e.g., in close proximity to buildings, pipelines
or other structures, the Contractor shall ensure that careful attention is given to the vibration
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levels to minimise nuisance.
2.7 MISCELLANEOUS
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2.7.1 Service Ducts
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1 The Contractor shall furnish and install new protection ducts of split PVC-U pipes, concrete
encased, to protect existing utility mains or cables where new pipelines are to cross such
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utility mains or cables.
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2 After the split PVC-U pipe has been placed around the existing utility mains or cables, the
pipe shall be wrapped twice with polyethylene film, 150 m thick, to prevent fresh concrete
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from entering the duct. The protection ducts shall be supported on suitable non-corrosive
spacers before placing the concrete encasement.
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3 All concrete work shall be in accordance with the requirements of Section 5 and concrete
encasement shall be with Grade 20 SRC concrete.
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2.7.2 Formation of Bunds and Embankments

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1 The material used in the formation of embankments bunds and other areas of fill shall be
obtained by the Contractor from sources approved by the Engineer. The material shall
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equate to selected excavated material or similar.

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2 Bund and embankment material at the optimum moisture content shall be built up evenly
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over the full width and compacted in layers not exceeding 300 mm in compacted depth. The
moisture content of material may require adjustment to that required to attain maximum
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density. Material which contains insufficient moisture to obtain the desired compaction will
require the incorporation of additional water by the use of approved sprinklers and mixing.
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3 Layers more than 300 mm below road formation levels shall be compacted to 90 % of the
maximum dry density. Layers less than 300 mm below road formation level shall be
compacted to 95 % of the maximum dry density. Maximum dry density shall be determined in
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accordance with CML 12-97
4 The Contractor shall ensure that material laid immediately next to a structure, concrete wall
or thrust block is well compacted. Hand operated vibrating plate compactors vibro-tampers
or power rammers shall be used. In other cases, compaction shall be carried out by vibrating
compactors smooth wheel or pneumatic tire rollers of types approved by the Engineer.
5 In forming bunds and embankments, the Contractor shall make allowance for consolidation
and shrinkage in attaining the dimensions of bunds and embankments shown on the
Drawings.
Part 02: Earthworks
6 The Contractor shall make due allowance for consolidation and settlement of embankments
and bunds both in width and height. Any subsidence that may occur during the period of
maintenance shall be corrected by the Contractor at no additional cost and to the satisfaction
of the Engineer.
7 Round tops of cut slopes in soil to not less than a 1.8 m radius, provided such rounding does
not extend offsite or outside easements and rights-of-way, or adversely impacts existing
facilities, adjacent property, or completed Work.
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END OF PART
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Part 03: Pipes and Fittings Materials
3 PIPES AND FITTINGS MATERIALS ....................................................................... 3

3.1 GENERAL .................................................................................................................................3
3.1.1 Scope 3
3.1.2 References 3
3.1.4 Submittals 5
3.1.5 Delivery, Handling and Storage 6
3.1.6 Pipe Materials 9
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3.2 VITRIFIED CLAY PIPES AND FITTINGS ..............................................................................10
3.2.1 Standards 10
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3.2.2 Manufacture 10
3.2.3 Inspection and Testing 11
3.2.4 Repair Couplings for VC Pipes 11
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3.3 CONCRETE PIPES AND FITTINGS ......................................................................................11
3.3.1 Standards 11
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3.3.2 Pipe Materials 11
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3.3.4 Plastic Lining 13
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3.3.5 Epoxy Coating 13
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3.4 GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS ..........................................14

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3.4.1 Standards 14
3.4.2 Design 16
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3.4.3 Pipes and Fittings Manufacture 17

3.4.4 General 17
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3.4.5 Buried GRP 17

3.4.6 Exposed GRP 23
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3.5 PVC-U PIPES AND FITTINGS ...............................................................................................25

1.1.1 Standards 25
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3.5.3 Joints 27
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3.6 ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS ..........................28

3.6.1 Standards 28
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3.6.3 Joints 28
3.7 DUCTILE IRON PIPES AND FITTINGS .................................................................................28
3.7.1 Standards 28
3.7.2 Exposed Joints 28
3.7.3 Buried Joints 29
3.7.4 Internal Lining 29
3.7.5 External Coating and Wrapping, Use and Materials 29
3.7.6 Factory Application of Tape Wrapping 31

3.7.7 Factory Applied Extruded Polyethylene Coating 31
3.8 FLANGE ADAPTERS AND FLEXIBLE COUPLINGS ...........................................................32
3.8.1 General 32
3.8.2 Flange Adapters 32
3.8.3 Flexible Couplings 33
3.9 PIPES FOR OTHER USE .......................................................................................................33
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3.9.1 Copper Tubes and Fittings 33
3.9.2 Hose and Appurtenances 33
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3.9.3 Stainless Steel Pipes, Tubes and Fittings 33
3.9.4 Carbon Steel Pipes and Fittings 34
3.10 MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES .......................................34
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3.10.1 Applicable Standards 34
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3.10.3 Fittings 37
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3.10.4 Pipes and Fittings for Gravity Applications 38
3.10.5 Testing of MDPE and HDPE Pressure Pipes and Fittings M 38
3.11 POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-PRESSURE
DRAINAGE AND SEWERAGE ...............................................................................................41
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3.11.1 General 41
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3.11.2 Resin 41
3.11.3 Minimum strength 41
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3 PIPES AND FITTINGS MATERIALS
3.1 GENERAL
3.1.1 Scope
1 This Part includes the manufacture, factory testing and supply of pipes and appurtenances of
different materials for use in pipelines.
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2 Related Sections and Parts are as follows:
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This Section
........................ Part 1 General
........................ Part 4 Pipeline Installation
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........................ Part 5 Valves, Penstocks and Appurtenances
........................ Part 6 Miscellaneous Metal Works
........................ Part 7 Miscellaneous GRP Works
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........................ Part 8 Protective Coatings and Painting
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........................ Part 11 Sewer Rehabilitation
........................ Part 12 Vacuum Sewerage System
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Section 5 Concrete
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Section19 Plumbing Works
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Section 20 Drainage Works to Buildings.

3.1.2 References
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1 The following standards or revised/updated versions are referred to in this Part:

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ANSI B16.3.................Malleable Iron Threaded Fittings

ANSI B16.5.................Steel Pipe Flanges and Flanged Fittings
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ANSI B16.9.................Factory-Made Wrought Steel Butt Welding Fittings

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ANSI B16.11...............Forged Steel Fittings, Socket Welded and Threaded

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ANSI B16.28...............Wrought Steel Butt Welding, Short Radius Elbows and Returns
ANSI B 36.19..............Stainless Steel Pipe
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ASTM A53 ..................Standard specifications for Pipe, Steel, Black and Hot-dipped, Zinc-
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coated Welded and Seamless

ASTM A105 ................Standard specifications for Forging, Carbon Steel, for Piping
Components
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ASTM A182 ................Standard specifications for Forged or Rolled Alloy-steel Pipe Flanges,
Forged Fittings, Valves and Parts for High Temperature Service
ASTM A234 ................Standard specifications for Piping Fittings of Wrought Carbon Steel
and Alloy Steel for Moderate and Elevated Temperatures
ASTM A240 ................Standard specifications for Heat-Resisting Chromium and Chromium-
Nickel Stainless Steel Plated, Sheet and Strip for Pressure Vessels
ASTM A312 ................Standard specifications for Seamless and Welded Austenitic Stainless
Steel Pipes
ASTM A403 ................Standard specifications for Wrought Austenitic Stainless Steel Piping
Fittings
ASTM A774 ................Standard specifications for As-Welded, Wrought Austenitic Stainless
Steel Fittings for General Corrosive Service at Low and Moderate
Temperature
ASTM A778 ................Standard specifications for Welded Unannealed Austenitic Stainless
Steel Tubular Products
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ASTM D1000 ..............Standard Test Methods for Pressure-Sensitive Adhesive-Coated
Tapes Used for Electrical and Electronic Applications
ASTM D1004 ..............Standard Test Method for Initial Tear Resistance of Plastic Film and
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Sheeting
ASTM D2412 ..............Standard Test Methods for External Loading Characteristics of Plastic
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Pipe by Parallel Plate Loading
ASTM D2584 ..............Standard Test Method for Ignition Loss of Cured Reinforced Resins
ASTM D3681 ..............Standard Test Method for Chemical Resistance of “Fiberglass” (Glass-
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Fiber-Reinforced Thermosetting Resin) Pipe in a Deflected Condition
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AWWA C209 ..............Cold-Applied Tape Coatings for the Exterior of Special Sections,
Connections, and Fittings for Steel Water Pipelines
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BS 65:1991.................Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for
use solely with surface water pipes and fittings
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BS 864........................Capillary and compression tube fittings of copper and copper alloy

BS 2494......................Elastomeric seals for joints in pipework and pipelines
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BS 2782......................Methods of testing plastics

BS 3063......................Dimensions of gaskets for pipe flanges
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BS 3396......................Woven glass fibre fabrics for plastics reinforcement

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BS 3532......................Method of specifying unsaturated polyester resin systems

BS 3749......................“E” Glass fibre woven rovings for the reinforcement of polyester and
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epoxy resin systems

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BS 4027......................Specification for Sulphate-resisting Portland cement

BS 4346......................Joints and fittings for use with unplasticised PVC pressure pipe
BS 5391...................... Acrylonitrile butadiene-styrene (ABS) pressure pipe
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BS 5392...................... Acrylonitrile butadiene-styrene (ABS) fittings for use with ABS

pressure pipe.
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BS 5556......................General requirements for dimensions and pressure ratings for pipe of

thermoplastic materials
BS 5911......................Concrete pipes and ancillary concrete products
BS 5955......................Code of practice for plastic pipework (thermoplastic materials)
BS 6076......................Tubular Polyethylene film for use as protective sleeving or buried iron
pipes and fittings
BS EN 197..................Cement
BS EN 295..................Vitrified clay pipes and fittings and pipe joints for drains and sewers
BS EN 545..................Ductile iron pipes, fittings, accessories and their joints for water
pipelines - Requirements and test methods
BS EN 598 ----------- ...Ductile iron pipes, fittings, accessories and their joints for sewer
pipelines - Requirements and test methods
BS EN 639..................Common requirements for concrete pressure pipes including joints
and fittings
BS EN 642..................Prestressed concrete pressure pipes
BS EN 1057................Copper and copper alloys
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BS EN 1092................Flanges and their joints
BS EN 1401................Plastic piping systems
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BS EN 12620..............Aggregates for Concrete
BS EN 13244..............Plastic piping systems
BS EN 14020..............Reinforcements. Specification for textile glass rovings
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BS EN 14118..............Reinforcement. Specifications for textile glass mats
BS EN 14364 & BS EN 1796 ---- Glass-reinforced thermosetting plastics (GRP)
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BS EN ISO 1456 ........Metallic and other inorganic coatings
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DIN 30674-3 ...............Coating of ductile cast iron pipes; zinc coating with protective covering
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ISO 4179 ....................Ductile Iron Pipes for Pressure and Non-Pressure Pipelines,
Centrifugal Cement Mortar Lining, General Requirements
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ISO 4633 ....................Rubber Seals - Joint Rings for Water Supply, Drainage and Sewage
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Pipelines - Specification for Materials.

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1 Pipes and fittings, except for those used in treated sewage effluent pipelines, shall be
suitable for carrying sewage at temperatures of up to 45C with hydrogen sulphide
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concentrations up to 400 mg/l.

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2 Treated sewage effluent pipelines shall be suitable for chlorine concentration up to 15 mg/l.
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3 Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting
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the following characteristics unless otherwise specified:

SO3 Content : 1.7 g/l
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Cl Content : 1.07 g/l

pH : 8.6
Conductivity : 4000 µs/cm
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4 The Contractor's attention is drawn to the stringent limits on infiltration detailed in Clause
4.5.2 of this section.
5 The Contractor shall be responsible for providing a jointing system as recommended by the
pipe manufacturer that enables the installation and use of the designated pipeline systems.
3.1.4 Submittals
1 The Contractor shall order materials to suit the construction programme and obtain the
Engineer’s approval of submittals before placing orders. The Contractor shall submit two
copies of the following documents for the approval of the Engineer:
(a) product data

(i) originals of catalogues and engineering data sheets for manufactured items.
Each item and option to be provided shall be clearly marked and each item not
to be provided shall be deleted
(ii) literature to show that products provided meet the requirements for material,
construction, operation, and tests
(iii) information on the following items as a minimum:
 pipes
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 flexible couplings
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 gaskets
 isolating joints
 sealant systems
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 linings and protective coatings
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(iv) manufacturer’s installation instructions for all items
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(v) certified reports for all tests and inspections designated herein, signed and
sealed, showing full compliance with referenced standards
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(vi) maintenance requirements and procedures
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(vii) period of guarantee for products
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(viii) Manufacturer’s test reports for hydrostatic proof testing, sustained pressure
testing and burst strength testing.
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(b) shop drawings

(i) Piping material, class, grade and joint type, thickness or schedule, seam or
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seamless, coating information if applicable.

(ii) fittings, couplings, and joints
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(iii) for concrete pipes, details of reinforcement, concrete and joints for straight
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(iv) pipes, specials and connections

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(c) design data

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(i) If glass reinforced plastic (GRP) pipes with a stiffness exceeding designated
values by more than 30 percent are proposed, the Contractor shall include in his
submittal complete structural design calculations indicating the effect of the
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proposed variation in pipe stiffness of the deformation modulus of the bedding

material or any other related aspect
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3.1.5 Delivery, Handling and Storage
1 Each pipe, fitting and special appurtenance shall be marked with permanent identification
which shall include but not necessarily limited to the following:
(a) nominal diameter

(b) name or trade mark of manufacturer
(c) serial number
(d) class of pipe, pressure rating in compliance with referenced standards
(e) date of manufacture

(f) type of service
(g) details on fittings such as angle of change and taper
(h) circular concrete pipes with asymmetrical reinforcement shall have the letter "T" clearly
marked on the inside and outside to indicate the top of the pipe when laid.
2 The acceptability of the pipes and fittings on delivery to the Site will be based on the results of
tests carried out by one or more of the following:
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(a) the manufacturer at the place of manufacturer
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(b) the Engineer
(c) a third party on behalf of the Engineer
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3 The Engineer shall be permitted at all reasonable times to visit places of manufacture to
witness tests.
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4 The Engineer may require checking of the dimensional accuracy of GRP pipes and fittings at
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the place of manufacture, the cost of such verification shall be borne by the Contractor.
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Transport, handling and storage of pipes and fittings shall be carried out as follows:
(a) in accordance with the manufacturer’s recommendations subject to the approval of the
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Engineer
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(b) effective precautions shall be taken to prevent damage to the pipe and fittings.
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6 During transport
(a) pipes and fittings shall be well secured and adequately supported along their length
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(b) bolsters and binding of approved type shall be used

(c) nesting of pipes (placing a smaller pipe inside a larger) may be permitted for pipes of
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certain materials and size provided that methods statements demonstrate that
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effective precautions will be taken to protect all pipe surfaces and coatings from
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damage
(d) no pipe shall overhang the end of a vehicle
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(e) pipes and fittings of plastic materials shall be covered.

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7 Handling shall be carried out as follows:
(a) pipes should be lifted singly and not handled as bunches

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(b) pipes shall be handled only by means of

(i) approved hooks, of the type having a plate curved to fit the curvature of the
inside of the pipe, on ends of sections
(ii) fabric slings not less than 250 mm wide
(iii) other methods approved for the pipe used
(c) use of wire rope, chains and fork lift trucks will not be permitted
(d) for strings of pipe longer than the standard length precautions shall be taken to avoid
curvature and longitudinal stress in excess of allowable limits
(e) pipes and fittings of plastic materials

(i) smaller than 300 mm diameter may be handled manually, larger than 300 mm
diameter and greater than 4 metres in length shall be lifted using fabric lifting
straps or large diameter rope slings positioned at a quarter of the pipe length
from each end
(ii) there should be enough slack in the slings to keep the hook approximately
600 mm over the pipe
(iii) steel chain or hooks shall not come into contact with the pipe
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(f) VC pipes and fittings shall be transported in pallets and handled only with suitable
equipment
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(g) pipes and fittings shall not be dropped or bumped
(h) pipes shall not be dragged over the ground
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(i) if rolled, pipes shall be rolled only over adequate timber bearers to prevent damage
(j) where necessary, chocks shall be used to prevent lateral movement of pipes.
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8 All pipes, fittings and materials shall be stored in accordance with the manufacturer's
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recommendations and the following:
(a) pipes may be stored in the open on a flat level area and raised above the ground on
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timber bearers so that the lowest point of any pipe or fitting is not less than 150 mm
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above the ground

(b) timber bearers not less than 200 mm wide and 75 mm thick to be provided at 4 m
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intervals maximum
(c) if on pallets or crated, on the pallets or in their crates until required
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(d) if not on pallets or not crated, stacked one above the other as follows:
in accordance with the manufacturer’s recommendations but not to a greater number
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of tiers than the following:

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........................ pipes  900 mm diameter 2 tiers

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........................ < 900 mm  600 mm diameter 3 tiers

........................ < 600 mm diameter 4 tiers
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(i) suitable protective packing shall be placed between tiers to the approval of the
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Engineer
(ii) wrapped pipes shall not be stacked
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(e) if spigot and socket, stacked so that successive pipe layers have sockets protruding
at opposite ends of the stack
(f) with pipes of different sizes and thickness stacked separately
(g) with maximum height of stacked pipes not exceeding 2 m, or that recommended by
the supplier if less than 2 m.
9 Pipes and fittings of plastic materials including GRP shall be:
(a) stored under cover and out of direct sunlight

(b) adequately supported along their length
(c) provided with a free flow of air around the pipe.
10 Storage of jointing materials shall be as follows:
(a) under cover

(b) rubber ring gaskets shall
(i) be stored in their original packing
(ii) not be exposed to sunlight
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(iii) protected from exposure to greases and oils
(c) gasket lubricants shall be stored so as to prevent damage to the container.
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11 Pipes and fittings shall be protected in storage to the approval of the Engineer by means of
an impermeable membrane which shall cover the pipes and fittings and separate them from
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the ground on which they are supported. The membrane shall be strong and durable in the
prevailing climate conditions.
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12 Pipes and fittings shall be subject to visual inspections after off-loading at site and before
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installation.
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The following procedures shall be followed for dealing with damaged pipes and fittings:
(a) pipes and fittings damaged during transportation handling and storage shall be set
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aside and the damage brought to the attention of the Engineer

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(b) pipes or fittings that show signs of corrosion or deterioration during storage shall
immediately be treated to arrest and prevent the corrosion or deterioration or
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removed from Site, as the Engineer directs

(c) proposals for repair shall be submitted in writing for the Engineer’s approval
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(d) no attempt shall be made to repair damage without the Engineer’s approval
if in the Engineer’s opinion the nature of any damage is such that the condition of a
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(e)
pipe has been impaired and cannot be repaired the pipe concerned shall not be
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incorporated in the Works

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(f) all rejected pipes shall be immediately removed from the Site
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(g) damaged pipe shall be replaced or repaired by the Contractor at his expense and such
repairs shall be to the approval of the Engineer
(h) the Engineer may require that any GRP pipe or fittings found to be damaged to be
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subjected to a further hydraulic test which shall be carried out by the Contractor, at the
Contractor’s expense, in accordance with the requirements of Subpart 4.5 of this
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Section.
3.1.6 Pipe Materials
1 For the purposes of this specification the following shall apply:
(a) Pipes of steel, glass reinforced plastic (GRP), PVC-U and polyethylene shall be
deemed to be flexible pipes.
(b) Pipes of concrete, vitrified clay and ductile iron shall be deemed to be rigid pipes.
3.2 VITRIFIED CLAY PIPES AND FITTINGS
3.2.1 Standards
1 Pipes and fittings for foul sewerage and surface water applications shall be manufactured to
BS EN 295.
2 Pipes and fittings for land drainage applications shall be manufactured to BS 65.
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3 Sealing rings shall be to BS 2494 or ISO 4633.
3.2.2 Manufacture
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1 Pipes and fittings shall comply with the following:
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(a) pipes shall have spigot and socket type joints.
(b) pipes shall be glazed both internally and externally.
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(c) all pipes shall be free of cracks, blisters, broken ends and other imperfections.
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(d) vitrified clay pipes shall have the minimum strength requirements shown on Table 3.2
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Table 3.2 – Minimum Strength Requirements
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Min. Crushing Strength (FN) kN/m

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Nominal Bore
(mm)
Foul / SW Land Drains
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(Non-Perforated) (Perforated)
100 28 28
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150 28 28
200 40 28
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300 60 34
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400 64 44
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500 80 60
600 96 -
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800 96 -
1000 95 -
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2 Joints shall be as follows:

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(a) Pipes and fittings shall be supplied with flexible mechanical joints of the spigot and
socket type joints.
(b) Sealing rings shall be of elastomeric material suitable for foul sewerage and
surfacewater drainage works, as the case maybe, conforming to BS 2494 or ISO 4633.
(c) Acceptance of VC pipes on delivery is dependent upon the Contractor demonstrating
that the joints are capable of meeting the water test requirement of Clause 4.5.2 of this
Section.
(d) Polypropylene sleeve couplings shall not be used.
3 Fittings shall be capable of withstanding the same load as the adjacent pipes or shall be
provided with concrete surround.
3.2.3 Inspection and Testing
1 Barrel impermeability, straightness, crushing strength and bending moment resistance and
chemical resistances tests shall be carried out in accordance with BS EN 295 at the
frequency designated for the crushing strength test.
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3.2.4 Repair Couplings for VC Pipes
1 Repair couplings shall be obtained from an approved manufacturer and shall consist of a
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moulded synthetic elastomeric sleeve which is fastened over the pipe ends by stainless steel
clamping bands and be complete with a stainless steel shear ring. The repair coupling shall
be suitable for use with vitrified clay pipes and shall include a bushing adapter when joining to
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a pipe of the same nominal bore but of a different outside diameter.
2 Repair couplings shall comply with the joint performance requirements of BS 65 and be
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capable of withstanding an external water pressure of 60 kPa without leaking.
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3 Sleeves and bushes shall comply with the requirements of BS EN 681-1. Clamping bands
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and shear ring shall be made from 300 series austenitic stainless steel.
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3.3 CONCRETE PIPES AND FITTINGS
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3.3.1 Standards
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1 Except as otherwise designated, concrete pipes and fittings shall conform to the
requirements of this Subpart following standard specifications:
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(a) reinforced and unreinforced, BS 5911

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(b) prestressed non-pressure concrete pipes, BS 5911.

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2 The strength requirement and other features of particular application shall be as specified in
this Subpart or designated in the contract specific documentation.
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3.3.2 Pipe Materials

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1 Cement used for manufacturing pipes and fittings shall be Ordinary Portland cement
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conforming to BS EN 197-1.
2 Aggregate shall conform to BS 882.

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3 Reinforcement shall conform to BS 4449 or BS 4483 as appropriate.
4 Admixture shall be used only with the written permission of the Engineer. The methods of use
and the quantities of admixtures used shall be subject to the approval of the Engineer.
Admixture containing calcium chloride will not be permitted.
3.3.3 Manufacture
1 Pipes and Fittings:
(a) Storage of concrete materials, mixing, curing and testing of concrete shall be in
accordance with the appropriate Clauses in Section 5. Any deviation from these
clauses shall be made only with the approval of the Engineer
(b) unless stated otherwise crushing strengths of pipes shall not be less than those
designated in BS 5911 for the designated classes of pipes.
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(c) Reinforced concrete pipes shall have a minimum effective length of 2.5 m except as
otherwise designated or required for special purposes such as curves, closures or
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built in pipes.
(d) Steel reinforcement shall be accurately placed in the concrete wall. The placement of
all steel shall not vary from the designated position in the pipe wall by more than
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 6 mm from the nominal position. In no case shall the cover to the reinforcement be
less than 25 mm.
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(e) The planes of the ends of the pipes shall be perpendicular to their longitudinal axis.
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2 Joints M
(a) except as specified in other Parts of this Section, pipe joints shall be supplied with
flexible mechanical joints of the spigot and socket type in accordance with BS 5911,
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double collar or sleeve type

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(b) gasket stock shall

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(i) comply with BS 2494.

(ii) be a synthetic rubber compound in which the elastomer is exclusively neoprene.
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(iii) solid compound shall contain not less than 50 % by volume of neoprene and
shall not contain reclaimed rubber or deleterious substances.
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(iv) stock shall be extruded or moulded and cured in such a manner that
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cross-sections are dense, homogeneous and free from porosity, blisters, pitting
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and other imperfections.

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(v) stock shall be extruded or moulded with smooth surfaces to the designated size
within a tolerance of  6 % measured on joint cross-section dimensions.
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(c) the sealing ring shall be confined in a contained groove on the spigot face of each
pipe section to properly position and confine the rubber gaskets in the annular space
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(d) each joint shall contain a neoprene ring gasket as follows:

(i) the gasket shall be the sole element depended upon for watertightness of the
joint.
(ii) the gasket shall be of circular cross-section unless otherwise approved by the
Engineer.
(iii) the length and cross-sectional diameter of the gasket, the annular space
(iv) provided for the gasket, and all other joint details shall be such as to produce a
watertight joint which shall not leak when pulled 13 mm over and above the
initial jointing allowance.
(e) the initial jointing allowance is the gap between the spigot and the shoulder of
the socket measured parallel to the centre of the pipeline and shall not be less than
6 mm or greater than 12 mm.
(f) Joints shall be capable of maintaining water tightness up to an angular deflection of 2°
from true, in any direction.
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3.3.4 Plastic Lining
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1 Where designated concrete pipes shall be lined with polyvinyl chloride plastic (PVC) liner
plate. The PVC liner plate material shall be as specified in Section 5 Part 14.6. The liner plate
shall be securely fixed to the formwork before pouring concrete and all in-situ welding of the
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liner plate shall be carried out by skilled labour using the methods specified by the
manufacturer. Purpose made units shall be used where required; e.g., at junctions.
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2 The installation of liner plates in concrete pipes or structures, and the sealing and welding of
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joints, shall be carried out in strict compliance with all applicable specifications, instructions
and recommendations of the plastic liner plate manufacturer. All welding of liner plate shall
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be carried out by properly trained and approved workmen.
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3 Once cast into the pipe, the liner shall be permanently and physically attached to the concrete
by the locking mechanism and shall not rely on an adhesive bond.
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4 The lining shall withstand a 100 kPa hydrostatic back pressure applied to the under surface
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of the lining without losing anchorage or without rupture.

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5 Damaged liner plate shall be repaired in accordance with the manufacturer’s

recommendation and to the approval of the Engineer.
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3.3.5 Epoxy Coating

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1 All exterior surfaces of concrete pipes shall be coated by the pipe manufacturer with a heavy
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duty, solvent free epoxy suitable for application to fresh concrete as specified in Section 5. A
minimum of two coats shall be applied to attain a minimum total dry film thickness of 400 m.
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1 Inspection procedures and tests shall be carried out at the place of manufacture. Pipes and
joints shall be hydrostatically tested in accordance with BS 5911.
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2 The performance of pipes shall be verified by the testing of random sample pipes in
accordance with the type of inspection and batch size mentioned. The pipes shall be subject
to rejection on account of non-compliance with the following:
(a) failure to pass hydrostatic test

(b) failure of the longitudinal concrete surfaces of joints to meet dimensional tolerances
(c) fractures or cracks
(i) passing through the shell, except that a single end crack that does not exceed
the depth of the joint shall not be cause for rejection; however
(ii) if a single end crack that does not exceed the depth of the joint exists in more
than 10 % of the pipes inspected, the defective pipes shall be rejected
(d) defects that indicate defective mixing and moulding
(e) surface defects indicating honeycomb or open texture
(f) spalls
(i) deeper than one half the depth of the joint
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(ii) extending more than 100 mm around the circumference
(iii) smaller than one half the depth of the joint or less than 100 mm around the
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circumference exist in more than ten percent of the pipes
(g) insufficient cover to the reinforcement.
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3.4 GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS
3.4.1 Standards
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1 All activities relating to this section of the particular specification shall comply with the
following or approved equal standard. The latest version of the standard indicated shall
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apply.
Statutory provisions shall always apply as amended from time to time.
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Generally applicable standards:

IN
BS EN 681 .................Elastomeric seals. Material requirements for pipe joint seals used in
water and drainage applications.
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BS EN 14364 .............Plastic piping systems for drainage and sewerage with or without
pressure. Glass reinforced-thermosetting plastics (GRP) based on
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unsaturated polyester resin (UP). Specification for pipes, fittings and

joints
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BS EN 1796................Plastic piping systems for water supply with or without pressure –

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Glass-reinforced thermosetting plastics (GRP) based on unsaturated

polyester resin (UP)
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CEN TS 14632 ...........Plastics piping systems for drainage, sewerage and water supply,
pressure and non-pressure - Glass-reinforced thermosetting plastics
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(GRP) based on unsaturated polyester resin (UP) - Guidance for the

assessment of conformity
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ISO 25780 ..................Plastic piping systems for pressure and non-pressure water supply,
irrigation, drainage or sewerage – Glass-reinforced thermosetting
plastics (GRP) systems based on unsaturated polyester (UP) resin –
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Pipes with flexible joints intended to be installed using jacking

techniques
ISO 3126 ...................Plastic pipes. Measurement of dimensions wall thickness table.
ISO 4633 ...................Joint rings for water supply, drainage and sewerage pipelines:
Specification for materials
ISO 1172 ....................Textile-glass-reinforced plastics, prepregs, moulding compounds and
laminates - Determination of the textile-glass and mineral-filler content
- Calcination methods
DIN 16 869 - Part 1 ...Centrifugally cast and filled glass fibre reinforced polyester resin pipes
- dimensions.
DIN 16 869 - Part 2 ...Glass-fibre reinforced polyester resin pipes (UP-GF) – Centrifugally
cast – filled Part 2: General quality requirements, testing.
DIN EN ISO 178 ........Plastics – Determination of flexural properties (ISO 178:1993)
DIN EN ISO 527-1 .....Plastics – Determination of tensile properties – Part 1: General
principles
DIN EN ISO 527-2 .....Plastics - Determination of tensile properties - Part 2: Test conditions
for moulding and extrusion plastics
ISO 15306 ..................Glass-reinforced thermosetting plastics (GRP) pipes — Determination
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of the resistance to cyclic internal pressure
ISO 10952 .................Plastics piping systems — Glass-reinforced thermosetting plastics
(GRP) pipes and fittings — Determination of the resistance to
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chemical attack for the inside of a section in a deflected condition
ISO 10928 ..................Plastics piping systems - Glass-reinforced thermosetting plastics
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(GRP) pipes and fittings - Methods for regression analysis and their
use
DIN 16966 -6 ..............Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint
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assemblies; collars, flanges, joint rings, dimensions
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DIN-16945 .................Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins
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DIN-16946 - Part 1 ....Cured casting Resins - Testing DIN-16946- Part 2 Cured casting
Resins - Types
DIN EN ISO 75 ..........Plastics – Determination of temperature of deflection under load
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DIN EN ISO 527-4 .....Plastics – Determination of tensile properties – Part 4: Test conditions
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for isotropic and orthotropic fibre-reinforced plastic composites

DIN EN ISO 10468 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination
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of the long-term specific ring creep stiffness under wet conditions and
calculation of the wet creep factor (ISO/DIS 10468:1999)
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DIN EN ISO 14828 ....Glass-reinforced thermosetting plastics (GRP) pipes – Determination

of the long-term specific ring relaxation stiffness under wet conditions
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and calculation of the wet relaxation factor (ISO/DIS 14828:1999)

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DIN EN 681-1 ............Elastomeric seals – Material requirements for pipe joint seals used in
water and drainage applications – Part 1: Vulcanized rubber
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DIN EN 1119 .............Plastics piping systems – Joints for glass-reinforced thermosetting

plastics (GRP) pipes and fittings – Test methods for leak tightness and
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resistance to damage of flexible and reduced articulation joints

ISO 10466 .................Plastics piping systems — Glass-reinforced thermosetting plastics
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(GRP) pipes — Test method to prove the resistance to initial ring

deflection
ISO 7685 .................... Plastics piping systems — Glass-reinforced thermosetting plastics
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(GRP) pipes — Determination of initial specific ring stiffness

ISO 8513 ....................Plastics piping systems — Glass-reinforced thermosetting plastics
(GRP) pipes — Determination of longitudinal tensile properties
ISO 8521 ....................Plastic piping systems — Glass-reinforced thermosetting plastics
(GRP) pipes — Test methods for the determination of the apparent
initial circumferential tensile strength
DIN EN 1447 .............Plastics piping systems – Glass-reinforced thermosetting plastics
(GRP) pipes – Determination of long-term resistance to internal
pressure
ISO 7509 ....................Plastics piping systems — Glass-reinforced thermosetting plastics

(GRP) pipes —Determination of time to failure under sustained
internal pressure
ASTM D2997 .............Standard Specification for Centrifugally cast “Fiberglass” (Glass-Fiber-
Reinforced Thermosetting-Resin) Pipe.
EN ISO 2078 ..............Textile glass — Yarns — Designation (ISO 2078)
ASTM D 3517-01 .......Standard Specification for “Fiberglass“(Glass-Fiber-Reinforced
Thermosetting-Resin) Pressure Pipe
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3.4.2 Design
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1 The design of GRP pipes, fittings and bedding shall be carried out by the pipe manufacturer
to enable the pipe to meet the requirements of the Works. The following general
requirements shall prevail for pipes and fittings:
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(a) they shall be designed to achieve a minimum working life of 60 years under all
applicable standard loadings, environmental and installation conditions
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2
(b) they shall have a minimum stiffness of 10,000 N/m
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(c) Non-pressure pipes and fittings shall be designed for a nominal pressure rating of PN
01 (1 bar)
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(d) Pressure pipes and fittings shall be designed for a normal operating pressure rating of
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PN16 (16 bar) to pressure ratings in ISO 25780, EN 14364 or EN 1796.
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(e) they shall convey a liquid with a temperature up to 45C

(f) they shall be designed to withstand up to 5% long term deflection in their installed
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conditions.
(g) all bends shall be long radius bends unless otherwise approved by the Engineer.
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(h) they shall be capable of withstanding a 95% lower confidence strain of 0.85% over 60
years without failure or cracking when tested in accordance with the strain corrosion
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type test requirements specified herein.

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(i) sewerage and drainage pipelines and fittings shall be designed to carry septic sewage
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having a maximum hydrogen sulphide concentration of 50mg/l at a temperature of

45C
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(j) irrigation pipelines and fittings shall conform to the water supply standards
(k) The manufacturer shall provide a valid Certificate of Conformity to EN 1796, EN 14364
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or ISO 25780 as applicable. The certificate shall be issued by an independent

certification body or authority.
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(l) For direct jack GRP pipes, the allowable jacking force shall be based on the minimum
wall thickness measured at the bottom of the spigot gasket groove where the wall
cross section has been reduced, and the mean longitudinal compressive strength of
the pipe. A minimum factor of safety of 3.5 in accordance with ISO 25780 shall be
used for the jacking force on a straight alignment. A reduced jacking force shall be
used when jacking to a curvature.
(m) Direct jack GRP pipes can be used for pressure and non-pressure applications.
3.4.3 Pipes and Fittings Manufacture
1 The pipes and fitting shall conform to either EN 14364 or EN 1796 for sewage or water
supply pipes. Jacking pipes shall comply with ISO 25780. The referenced test standards
therein have to be fulfilled.
3.4.4 General
1 All GRP components shall be designed and fabricated by one manufacturer.
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2 GRP pipes and fittings shall be manufactured by an approved process utilising a mandrel or
rotating mould incorporating equipment to accurately control the quantities and placement of
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all resins, glass and aggregates.
3 Use resins, reinforcement and aggregates to produce pipes and fittings, which when
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combined as a composite structure will satisfy the performance requirements of this section
of the specification.
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4 Internal and external surfaces shall be free from irregularities, which would impair the ability
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of the component to conform to the requirements of EN 14364, EN 1796 or ISO 25780.
3.4.5 Buried GRP

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G
1 The pipes and fittings shall be constructed using chopped and /or continuous glass filaments,
strands or roving, mats, synthetic veils or fabric, and polyester / vinyl ester resin, aggregate
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and fillers. If applicable, additives necessary to impart specific properties to the resin may be
used, subject to the approval of the Engineer.
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2 Filament Wound (FW) GRP Pipes and Fittings

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(a) Resins
Vinyl ester shall be used in the internal resin rich liner of the pipes and fittings.
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Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
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Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
Resins shall be cured to achieve a minimum of 90% of the manufacturer’s
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recommended Barcol hardness value.

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(b) Additives
The use of additives such as fire retardants, UV inhibitors or coloured pigments or
dyes shall only be used for specific project based applications and their use shall be
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subject to the approval of the Engineer.

(c) Glass reinforcement
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The glass used for the manufacture of the reinforcement shall be type “E” (alumina-
calcosilicate glass), type “C” (alkali-calcium glass) or type “ECR” (alumina-borosilicate
glass).
The reinforcement shall be made from continuous drawn filaments of glass and shall
have a surface treatment compatible with the resin to be used. It may be used in any
form, e.g. as continuous or chopped filaments, strands or rovings, mat or fabric.
(d) Aggregates
Aggregates shall be clean, graded silica sand containing no impurities and a maximum
moisture content of 2%. The maximum particles size of the sand aggregate shall not
exceed 0.8mm.
The overall sand content of the pressure pipes and fittings shall not exceed 30% by
weight.
The overall sand content of the non-pressure pipes and fittings shall not exceed 60%
by weight.
(e) Fillers
Fillers (other than silica sand aggregate) shall only be permitted if required for a
particular project application and be subject to the approval of the Engineer following
satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
hours.
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(f) Wall construction
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Lining Layer
(i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding
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10% by weight. The remainder of the lining shall consist of layers of vinyl ester
resin and powder bound ECR acid resistant glass chopped strand mat or roving,
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depending on the method of manufacture, with a glass content of between 25%
and 35% by weight.
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(ii) Sand aggregate shall not be used in the lining layer.
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Structural Layer
(iii) The structural layer shall comprise Type E or ECR glass reinforcement and a
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thermosetting isophthalic polyester resin with or without sand aggregate.

IN
(iv) The layer shall be built up in layers of Type E or ECR acid resistant glass chop
roving or continuous roving.
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(v) The manufacturing process shall ensure that no aggregate becomes embedded
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in the internal resin rich liner layer.

Outer Layer
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(vi) Pipes shall be provided with a resin rich layer with C glass veil reinforcement.
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(vii) The resin used in the outer layer shall have a Glass Transition temperature of at
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least 75C.
(viii) The use of special finishes is permitted when the pipe or fitting is expected to be
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exposed to extreme climatic, environmental or ground conditions. These may

include the provision of a sand layer, pigments or inhibitors for UV protection or
fire retardation, subject to the approval of the Engineer.
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(g) Bends and Fittings

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Bends and fittings shall be equal or superior in quality and performance to the
corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been hydraulically tested successfully.
3 Centrifugally Cast (CC) GRP Pipes and Fittings
(a) Resins
Vinyl ester shall be used in the internal pure resin liner of the pipes and fittings.
Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
(b) Additives
The glass used for the manufacture of the reinforcement shall be Type E or ECR
glass.
The reinforcement shall be made from chopped glass filament in long and short fibres
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and shall have a surface treatment compatible with the resin to be used.
(d) Aggregates
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exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
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(e) Fillers
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ID
hours. M
Lining Layer
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(i) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
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resin without glass reinforcement and sand aggregates.

LT
(ii) The barrier and transition layers between the pure resin lining layer and the
structural layer shall be to suit the manufacturing process.
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Structural Layer
(iii) The structural layer shall comprise glass reinforcement and a thermosetting
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isophthalic polyester or vinyl ester resin with or without sand aggregate.

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(iv) The layer shall be built up in layers of ECR acid resistant glass chopped fibres.
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(v) The manufacturing process shall ensure that no aggregate becomes embedded
in the inner pure resin liner layer.
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Outer Layer
(vi) Pipes shall be provided with an outer layer formed of a mortar of resin and sand
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aggregates with no glass reinforcement.

(vii) The resin used in the outer layer shall have a Glass Transition temperature of at
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least 75C.
(viii) An outer protection layer shall be provided which has a minimum of 60% sand
for corrosion protection.
(ix) The use of special finishes is permitted when the pipe or fitting is expected to be
(x) The transition layers between the structural layer and the outer layer shall be to
suit the manufacturing process.
(g) Bends and Fittings

Bends and fittings shall be equal or superior in quality and performance to the
corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been successfully pressure tested.
4 Direct Jack GRP Pipes
(a) Resins
Vinyl ester resin shall be used in the internal pure resin liner of the pipes. Isophthalic
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or vinyl ester resin shall be used in the structural layer of the pipes. Vinyl ester or
isophthalic resin shall be used in the outer layer of the pipes.
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(b) Additives
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D
ID
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The glass used for the manufacture of the reinforcement shall be Type E or ECR acid
resistant glass.
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The reinforcement shall be made from chopped glass filament in long and short fibres
and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric
IN
and shall have a surface treatment compatible with the resin to be used.
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(d) Aggregates
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exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
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(e) Fillers
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C
hours.
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Lining Layer
(i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding
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10% by weight. The remainder of the lining shall consist of layers of vinyl ester
resin and powder bound ECR acid resistant glass chopped strand mat or roving,
depending on the method of manufacture, with a glass content of between 25%
and 35% by weight, when the filament wound manufacturing process is used.
(ii) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
resin without glass reinforcement and sand aggregates when the centrifugal
manufacturing process is used.
(iii) The barrier and transition layers between the pure resin lining layer and the
structural layer shall be to suit the manufacturing process.
Structural Layer
(iv) The structural layer shall comprise glass reinforcement and a thermosetting
isophthalic polyester or vinyl ester resin with or without sand aggregate.
(v) The layer shall be built up in layers of Type E or ECR acid resistant glass
chopped fibres.
(vi) The manufacturing process shall ensure that no aggregate becomes embedded
in the inner pure resin liner layer.
ST
Outer Layer
(vii) Pipes shall be provided with an outer layer formed of a mortar of resin and sand
EA
aggregates with no glass reinforcement.
(viii) The resin used in the outer layer shall have a Glass Transition temperature of at
least 75C.
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(ix) An outer protection layer shall be provided which has a minimum of 60% of sand
for corrosion protection.
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(x) The use of special finishes is permitted when the pipe is expected to be
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(xi) The transition layers between the structural layer and the outer layer shall be to
suit the manufacturing process.
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(xii) The outer surface of the pipes shall be smooth with a resin rich topcoat 0.3mm
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thick.
(g) Longitudinal Compressive Strength
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Proof of compression strength shall be supplied by testing all pipe types using the
procedure set out in Annex A of ISO 25780.
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The test results of compressive properties obtained from coupon or spool test
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specimens may be used. As described in ISO 25780, the manufacturer shall show the
correlation of the results obtained from coupons or full spools by means of initial type
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tests. The pipes shall meet the following requirements for the initial longitudinal
compression properties:
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Table 3.4.1 : Longitudinal compressive strength for direct jack GRP pipes
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Mean
Minimum compressive
Specimen Pipe quality compressive
strength (single value)
strength
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Rebated and grooved with filler 80 MPa 90 MPa

specimen
Coupon specimen with filler 90 MPa 100 MPa
Rebated and grooved without filler 70 MPa 80 MPa

specimen
Coupon specimen without filler 80 MPa 90 MPa

(h) Dimensions
The manufacturer shall confirm that the outside diameter of the pipe conforms to ISO
25780.
The outside diameter of the jacking pipe shall be compatible with the jacking machine.
The nominal length of the pipe shall preferably be 1m, 1.5m, 2m, 3m or 6m. Other
lengths shall be permitted to suit a particular project requirement.
The jacking force shall be transmitted face to face on the pipe joint without the use of
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packer rings, unless required for a specific project application. The permitted deviation
from squareness across the joints external diameter shall be as tabled below:
Table 3.4.2 : Permissible deviation from squareness across a joint’s external diameter
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Manufacturer’s declared outside Deviation of
diameter dOD mm squareness mm
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dOD ≤ 300 0.5
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300 < dOD 1.0
ID
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(i) Marking of jacking pipes
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Markings shall meet the requirements for the application and conform to ISO 25780.
Designations to meet special quality requirements as item 6 below are permissible.
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The marking of the pipe shall be visible on the external and internal surfaces of the
jacking pipe.
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5 Wall thickness
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The minimum total wall thickness, including the liner and outer protective layer shall be
declared by the manufacturer, which shall be complying with the standard performance
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criteria.
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The wall thickness at any point on the pipe and the spigot shall not be less than the
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manufacturer’s declared values.

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6 Abrasion resistance
The pipes shall be resistant to abrasion when tested according to CEN TR 15729 over
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100,000 cycles. There shall be no evidence of free glass fibres on the inner surface of the
pipe.
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7 Markings
All pipes including cut lengths and all fittings before dispatch from the pipe manufacturer’s
works shall be indelibly marked as follows on the external and internal surfaces.
(a) The manufacturer's name, initials, or identification mark.

(b) The nominal internal diameter in millimetres.
(c) The length in metres.
(d) The classification i.e. pressure rating, stiffness.
(e) The date of manufacture and batch number.

(f) A stamp to show that they meet the required inspection requirements and hydraulic
tests at the point of manufacturer.
(g) Identification number stencilled on the inside and outside at each end. The same
number shall appear on all record sheets and documents relating to the manufacture
delivery and testing of that pipe.
(h) The manufacturing standard.
ST
(i) The project or contract number.
8 Joints
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Except where otherwise detailed on the Drawings, all buried pipes and fittings shall have non-
end-load-bearing flexible joints of spigot type or GRP sleeved couplers with EPDM rubber in
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full faced elements or rings in accordance with BS / DIN EN 681; manufactured according to
the individual manufacturing technique and supplied as an integral part of the pipe or as
separate fittings. The elastomeric sealing gaskets shall provide the sole means of
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maintaining joint watertightness. The sealing gaskets shall be supplied by the pipe
ID
manufacturer.
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Joints in direct jack applications (non-pressure application) can also be of stainless steel
Grade 316 Ti (EN 1.4571) couplers with approximately the same outside diameter as the
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pipe so that the joints are essentially flush with the pipe outer surface.
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The manufacturer shall declare the maximum draw for which each flexible joint type is
designed.
LT
The manufacturer shall declare the maximum allowable angular deflection and the maximum
SU
draw for which each locked joint type and flexible joint type are designed.
All joints shall remain watertight for all combinations of angular deflection and draw up to the
N
maximum allowable values. In addition, pipe joints for pipelines laid in open cut trenches
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shall be capable of withstanding an external pressure differential equivalent to +10m head of

water without leakage in the straight, deflected and drawn positions.
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When a pipe is cut or turned down in order to form a joint, the exposed faces shall be fully
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sealed with a continuous coating of vinyl ester resin with a minimum of 1.5mm thick.
Wrapped or cemented joints shall only be used subject to the approval of the Engineer.
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3.4.6 Exposed GRP

H
The use of GRP pipes and fittings for exposed service shall be subject to the approval of the
Engineer. The exposed pipes and fittings shall be designed to resist all bending stresses,
thrust forces, surge pressures, negative pressures, thermal and vibratory forces.
1 Exposed pipe and fittings shall be manufactured in the same manner and with the same
materials as buried pipe, along with the following requirements unless otherwise approved by
the Engineer.
(a) An outer protective surface layer shall be provided consisting of a topcoat of UV

inhibitor and resin with or without glass reinforcement to form a resin rich layer with a
minimum thickness of 0.3mm. The outer protective surface layer shall be designed to
resist other project specific extraneous causes (atmospheric conditions, mechanical
damage and chemical stress etc.) as described in the project specification.
2 Exposed pipes and fittings inside treatment plant buildings, process structures, pumping
stations, and valve chambers shall use PN 16 flanged joints:
(a) Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed
ST
with epoxy or vinyl ester resins only.
(b) All bolts shall be stainless steel grade 316.
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(c) Flanges shall be drilled to BS EN 1092 (metric units) resp. DIN 16966-1 type PN16.
(d) Flanged pipe joints shall incorporate an annular gasket covering the full face of the
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flange. Gaskets to be 3mm thick self-energised EPDM or nitrile rubber (NBR) with
embedded stainless steel inlay O rings. The gaskets shall have a shore hardness of
D
60±5.
ID
(e) When flanged joints are to be made, secure the bolts and the nuts initially to finger
tightness. Thereafter the final tightening of the nuts shall be effected by torque
M
spanners in such sequence that diametrically opposite nuts are tightened together to
achieve the manufacturers recommended torque.
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3 External exposed pipes and fittings shall use fixed laminated joints with expansion bellows
IN
and be supported in accordance with the manufacturer’s requirements.

LT
4 The exposed pipeline shall be protected by bollards, lateral sand bunds etc. where there is a
risk of physical impact.
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1 A pipe type test group consists of a range or family of products made such that the results of
N
the long-term type tests are applicable to all products in the group. A pipe type test group
shall be made of products:
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a) manufactured by the same process;

C
b) with the same material specifications;

ER
c) with the same pipe wall construction (i.e. the sequence of layers, layer
compositions, material properties and design method for using the results of the
long-term type tests in determining the pipe wall for all combinations of DN, PN
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and SN);
d) tested with the same loading condition (i.e. uniaxial or biaxial load).
H
2 The pipe manufacturer shall submit type test results according to EN 14364 or ISO 25780 for
each product group.
3 Strain corrosion tests shall be carried for each class and diameter range, where applicable,
according to ISO 25780 and ISO 10467, as a type test generally in accordance with ASTM
D3262 resp. ISO 10952. The strains shall be at levels at which failure can be predicted from
the strain corrosion type test results to occur at 100 hours and 1,000 hours. No failures shall
be below the lower 95% confidence limit of the type test regression line.
4 The calculated failure strain at 60 years from the results of the quality control test using the
least squares method shall not be less than 0.85%. In the event that a specimen fails the
strain corrosion test all pipes in that class and diameter range, where applicable, pertaining to
that batch which has been manufactured or installed shall be rejected.
5 The pipe manufacturer shall carry out the following Inspection Tests. The results of these
tests shall be made available to the Engineer who shall also be allowed to witness some or
all of the tests.
(a) One pipe in every 100 of each type and size of manufactured item shall be tested for
loss of ignition in accordance with ASTM D2584 resp. ISO 1172.
(b) The liner thickness of pipes, fittings and couplings shall be measured in accordance with
Section 6 of ASTM D3567 resp EN 3126. A liner check shall be carried out for one in
every 100 of each type and size of manufactured item. A minimum of one item of each
type and size shall be tested. The liner thickness shall not be less than 1mm at any
ST
pitted point.
(c) Data for the above tests shall be submitted to the Engineer. The data shall be traceable
to the supplied pipes with a unique number as "Batch no", the test data shall hold all the
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above mentioned tests samples results under this batch no. The batch no. shall be
clearly marked as ID on each length of produced pipes.
6 Checks will be carried out by the Engineer at Site. The Contractor shall destroy or indelibly
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mark as rejected and remove from Site any pipes or fittings found at any time failing to meet
dimensional criteria or any of the following quality criteria:
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(a) scratches shall be no deeper than 0.3 mm and no reinforcing fibres shall be exposed
ID
(b) no cracks shall be present on the inside of pipes. Hair cracks on the outside may be
permitted with repair if not longer than 200 mm circumferentially or 6 mm longitudinally.
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Impact cracks shall not affect more than 3 % of surface area
(c) no delaminations shall be evident
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(d) no impact or other damage to pipe ends shall be evident. The end surface of pipe or
fitting shall be completely covered with resin and free from cracks, porosity, bubbles,
IN
voids, exposed reinforcement or extraneous matter

LT
(e) no protruding fibres permitted on jointing surfaces

(f) no other protuberances. Small globules or resin projections permissible if not more than
SU
25 % of area is affected. Jointing surfaces shall be completely free of any such flaws.
Ridges formed by resin shall not exceed 1.5 mm in depth
(g) air voids, blisters, bubbles are not acceptable if greater than 5 mm diameter or 1 mm
N
depth. Subject to the approval of the Engineer, if less than 0.5% of internal areas are
O
affected, such defects may be ground out and repaired

(h) not more than 5 % of the internal or 10 % of the external surface shall be affected by
C
pitting. No individual pit shall be more than 1 mm diameter or 0.5mm depth

ER
(i) wrinkles and indentations shall not be more than 2mm deep and not more than 3 % of
surface area affected. Subject to the approval of the Engineer, if not more than 5 mm
deep and 0.5 percent of surface area is affected, such defects may be repaired
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(j) any pipe which when resting freely on the ground and not subjected to any loads other
than its own weight exhibits a deflection of more than 2%, measured along the diameter,
shall be rejected and removed from the Site.
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3.5 PVC-U PIPES AND FITTINGS
1.1.1 Standards
1 Except as otherwise indicated, materials and workmanship described in this section shall
conform to the latest editions of the following standards:
ASTM D1599 ..............Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe,
Tubing and Fittings
AWWA M23 PVC Pipe - Design and Installation
BS 3505/3506 - Polyvinyl Chloride Pressure Pipe
BS EN 1401 - Plastic piping for non-pressurised underground drainage & sewerage

BS EN 1452................Plastic piping systems for water supply (UPVC)
DIN 8061 ....................Unplasticised polyvinyl chloride pipes - general quality requirements &
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testing
DIN 8062: 1988 ..........Unplasticised polyvinyl chloride (PVC-U, PVC-HI) pipes – dimensions
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DIN 8063: 1986 ..........Pipe joint assemblies & fittings for unplasticised polyvinyl chloride
(PVC-U) pressure pipelines
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ISO 1452 ....................Pipes and fittings in PVC –U pipes for water supply
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2 The strength requirement and other features of particular application shall be as specified in
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this Subpart or designated in the contract specific documentation.
3.5.2 Manufacture
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1 UPVC pipe shall be provided in standard 6 metre lengths, unless otherwise specified,
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detailed or required on the approved plans. Shorter lengths, up to 3 metres, will be permitted
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when authorised by the Engineer. Field cut lengths of pipe used as closures may not be
shorter than 0.75 metre in length and must be approved by the Engineer. Solvent welded
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pipes may be permitted in sizes of 100mm and less.

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2 For sewerage service, PVC-U pipes 200 mm in diameter may be supplied in lengths up to
4 m. PVC-U pipes 150 mm in diameter and less shall be supplied 50 percent in lengths not
exceeding 2 m and 50 percent in lengths not exceeding 4 m.
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3 UPVC Pipes shall be SDR17 as a maximum and shall have be designed to withstand a
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0 0
nominal operating pressure of PN16 at 25 C (equivalent to PN10 at 45 C) unless otherwise
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specified in the Contract Documents.

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4 All joints for UPVC Pressure Pipe shall be integrally cast, spigot and socket joints, or plain
end with EPDM rubber ring couplings. Joints shall be of the same pressure rating as the pipe.
Solvent weld joints are not permitted for TSE Mains. Gaskets and lubricants shall be made
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from materials that are compatible with the plastic material and with each other when used
together. They shall not support the growth of bacteria and shall not adversely affect the
potable qualities of the water that is to be transported. One elastomeric gasket shall be
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furnished with each length of socket-end pipe.
5 Pipe shall have a minimum internal diameter equal to or greater than the pipe size shown on
the Drawings and Bills of Quantities. SDR shall be defined as outside diameter divided by
wall thickness. Acceptable PVC pipe shall have common profiles for interchangeability
between rough barrel dimensions, couplings, ends and elastomeric gaskets so as to facilitate
future repairs. When assembled, the pipe shall have only one gasket per socket and spigot
end.
6 Pipes delivered to site shall be no more than 12 months old. The Engineer reserves the right
to reject the pipes older than 12 months old.
3.5.3 Joints
1 Solvent welded joints shall not be permitted for sewerage pipelines and all jointing shall be by
socket and spigots with sealing rings which shall conform to BS 2494.
2 Unless otherwise designated, irrigation pipework up to 100 mm in diameter shall be solvent
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welded in accordance with BS 4346 Part 1.
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1 Inspection and testing for sewer pipes shall be in accordance with an approved inspection
and test plan.
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2 Inspection and testing for irrigation pipes shall be in accordance with an approved inspection
and test plan.
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3 Test certificates shall be provided by the manufacturer.
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All pipes may be subject to inspection at the place of manufacture in accordance with the
provisions of the referenced standards as supplemented by the requirements herein. The
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Contractor shall notify the Engineer in writing of the manufacturing starting date not less than
14 calendar days prior to the start of any phase of the pipe manufacture.
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5 During the manufacture of the pipe, the Engineer shall be given access to all areas where
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manufacturing is in process and shall be permitted to make all inspections necessary to

confirm compliance with the Specifications.
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6 The Contractor shall perform said material tests in accordance with the requirements of the
Contract Documents. The Engineer shall have the right to witness all testing conducted by
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the Contractor, provided that the Contractor’s schedule will not be delayed for the
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convenience of the Engineer.

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7 In addition to those tests specifically required, the Engineer may request additional samples
of any material for testing by the Engineer.
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8 All expenses incurred in obtaining samples for testing shall be borne by the Contractor at no
additional cost to the Contract.
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1 All fittings shall be push-on joint with mechanical fittings. Fittings shall be in uPVC material
compatible with the above specified pipe and having the same minimum Class and Pressure
Rating. The fittings when connected to the main pipe shall provide an integral system
capable of withstanding the working and test pressure.
3.6 ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS
3.6.1 Standards
1 Acrylonitrile butadiene-styrene (ABS) pipes and fittings for pressure pipes shall conform to
BS 5391 and BS 5392.
3.6.2 Manufacture
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1 Unless otherwise designated, ABS pipes and fittings shall be class E and manufactured in
accordance with BS 5391 and BS 5392.
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3.6.3 Joints
1 ABS pipes shall be provided with socket and spigot joints, sealed with elastomeric sealing
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rings conforming to BS 2494.
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1 Inspection and testing for pipes and fittings shall be in accordance with BS 5391 and
BS 5392.
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3.7 DUCTILE IRON PIPES AND FITTINGS
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IN
3.7.1 Standards
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1 Unless otherwise stated in the Contract Documents ductile iron pipes and fittings for pipes
shall comply with BS EN 545 and shall be suitable for an allowable operating pressure (PFA)
of 16 Bar and an allowable maximum operating pressure (PMA) of 20 bar.
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2 Unless otherwise stated in the Contract Documents, flanges on ductile iron pipework and
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fittings shall comply with BS EN 1092-2 and shall be PN16.

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3 All puddle flanges shall be cast integrally with the wall piece.
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3.7.2 Exposed Joints

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1 Ductile iron flanged pipes shall be furnished with integrally cast flanges or screwed on flanges
faced and drilled to class designation. Steel bolts and nuts shall be supplied with two
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washers per bolt. Bolt length shall be such that after the joints are made up, the bolts shall
protrude through the nut, but not more than 12 mm. Bolts shall be stainless steel grade to
BS 970 Grade 316 S31.
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2 Gaskets shall be compatible with the fluid to be conveyed. For treated sewage effluent
pipelines, EPDM gaskets shall be used. Gaskets shall be able to withstand a pressure of
PN 16 for a 24 h test period. Thickness of gaskets shall be such that, when jointed in
accordance with manufacturer’s instructions, the joint shall provide a positive seal for the
range of pressures likely to occur in the pipeline under the maximum joint deflection
permitted.
3 Pipes and fittings in chambers and pumping stations shall have flanged joints unless detailed
otherwise. Flanges shall comply with BS EN 1092-2 and shall be PN16 unless a higher
pressure rating is detailed elsewhere.
3.7.3 Buried Joints
1 Pipes and fittings to be buried shall have flexible joints unless detailed otherwise.
3.7.4 Internal Lining
1 Pipes and fittings shall be lined internally with one of the following linings:
(a) Polyurethane lining minimum thickness 1,000 micron
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(b) Fusion bonded epoxy powder lining minimum thickness 500 microns
(c) Ceramic epoxy lining minimum thickness 1,000 micron
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2 All coatings shall be factory applied in strict accordance with the lining manufacturer’s
specification. Pipes shall be blast cleaned or ground to the equivalent of BS EN ISO 8501-1,
BS 7079:A1, SA 2.5 prior to application of the products.
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3 All liners shall comply with the following standards:
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(a) adhesion to pipe (ASTM D4541) Min 10 MPa
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(b) impact resistance (ASTM2794) Min 10 J M
(c) abrasion resistance (AST D4060, 1kg x 1000cycles) Max 100 mg
(d) vapour permeability (ASTM D1653, Wet cup method) 1.0g/m2/24hr
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(e) immersion test 20% sulphuric acid (ASTM D-714-87) No effect after 2 years
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(f) salt spray test (ASTM B117 – 1,000 hours) pass

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(g) spark holiday test voltage V = 248T0.5, where T = thickness of lining in microns
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(h) any defect found in the lining shall be repaired at the manufacturers plant before
shipment.
4 Internal socket end of pipes shall be protected with a minimum thickness of 300m of epoxy.
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5 All pipes shall be clearly marked to indicate the type of lining as follows:
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(a) PU – Polyurethane
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(b) FBE – Fusion bonded epoxy

(c) CE – Ceramic epoxy
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3.7.5 External Coating and Wrapping, Use and Materials

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1 External coatings for ductile iron pipes shall be factory applied to the approved pipe
manufacturer’s standards and conform to one of the following specifications.
Table 3.2 External DI Pipe Coating Systems

Applicable
Inner coat Middle Coat Final Coat
Standards
200g/m2 zinc 150m epoxy Black fusion or hot melt BS EN 598, BS 6076
adhesive bonded and ISO 8179-1
polyethylene sleeving
of nominal thickness
1000m
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200g/m2 zinc 150m epoxy Black tape self BS EN 598, ISO 817,
adhesive bituminous AWWA C2009
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resin on PVC backing
layer complying with
AWWA C2009 Section
24 Type 1. 55%
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overlap.
Nil Nil Polyurethane as Part 3 NF A48-851
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– 3.7.4 minimum
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thickness 2000m
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2 Laminate tape shall have the following characteristics:
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IN
Table 3.3 Laminate Tape Properties
Pipes Pipes
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Applicable
Parameter
Standard 600mm dia 600mm dia
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Overall thickness ASTM D 1000 1.1mm 1.6mm
PVC backing thickness ASTM D 1000 0.3mm 0.7mm

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PVC backing thickness if ASTM D 1000 0.5mm 0.5mm

fabric reinforcement in
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bituminous layer
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Tensile Strength BS 2782 7.5N/mm 12.0N/mm

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Elongation BS 2782 200% 200%
Tear Resistance ASTM D 1004 19N/mm 50N/mm

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Adhesion to steel ASTM D 1000 1.0N/mm 2.0N/mm

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Adhesion to self ASTM D 1000 1.8N/mm 1.8N/mm
Impact resistance (single DIN 30672 8.0Nm 10.0Nm

layer)
Dielectric strength BS 2872 25,000V 30,000V
Insulation resistance BS 2782 1,000,000 1,000,000

megohms megohms
Water vapour BS 2782  0.65  0.65
2 2
permeability g/m /day g/m /day
3 Spigot ends of pipes that are tape or polyethylene wrapped shall not be wrapped over the
depth of engagement of the spigot with the socket or mechanical coupling but shall be coated
with a minimum thickness of 300m of epoxy.
3.7.6 Factory Application of Tape Wrapping
1 Before primer application, all oil and grease shall be removed with an approved solvent.
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Surfaces to be coated shall be cleaned by mechanical brushing to remove loose corrosion
products, welding slag, loose factory applied bituminous paint or any other foreign matter and
achieve a surface finish equivalent to mechanical scraping and wire brushing as specified in
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Clause 8.3.5 of this Section. All surfaces shall be solvent wiped after blast cleaning.
2 Primer shall be applied to all surfaces to be wrapped immediately following completion of
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surface preparation.
3 Primer shall be allowed to dry before wrapping. Primer application shall be limited to the
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amount that can be wrapped during the working day.
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4 Tape shall be applied spirally to provide a 55 % overlap and with sufficient tension to result in
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constant adherence without voids or wrinkles. On completion of the wrapping the surface
shall be smoothed to ensure completely sealed overlaps and the absence of air pockets
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under the tape. The width of the tape shall be suitable to conform to the size and shape of
the pipeline being wrapped.
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5 On completion of the wrapping, all tape wrapping shall be checked for continuity by a
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“Holiday” detection unit. Any Holidays detected shall be repaired by over-wrapping with tape
and the wrapping retested.
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6 Bond/adhesion tests shall be carried out on all tape wrappings not more than 24 hours after
completion of wrapping.
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7 Test certificates shall be provided by the manufacturer.

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3.7.7 Factory Applied Extruded Polyethylene Coating

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1 Extruded polyethylene coating shall be factory applied to preheated epoxy primed pipes and
fittings to provide a minimum finished thickness of 2.0 mm. The coating shall be resistant to
peeling, free from imperfections, and shall be tested for continuity using a minimum 10 kV
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spark tester. The polyethylene coating shall be stabilised to prevent ultraviolet and thermal
degradation.
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1 Inspection procedures and tests for DI pipes and fittings shall be carried out in accordance
with BS 4772.
2 The Contractor shall provide Manufacturer’s type and quality control test certificates to be
traced to the pipe cast number, heat number or lot number.
3 Manufacturer’s certificates shall state the relevant British or ISO standards to which the pipes
and fittings supplied comply.
4 The repairs to cement mortar linings, if permitted by the Engineer, shall comply with the
requirements of the designated thickness, minimum bore and surface conditions.
5 In addition to the prescribed testing, the pipes and fittings shall be subjected to visual
inspection at the place of manufacturer and at Site and will be rejected if the pipes are
incorrectly marked or have defects outside the ranges permitted.
3.8 FLANGE ADAPTERS AND FLEXIBLE COUPLINGS
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3.8.1 General
1 In addition to the types of joints typically designated for each type of pipe, flange adaptors
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and flexible couplings may be designated particularly for pressure pipelines.
Flange adaptors and flexible couplings shall:
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(a) be manufactured from rolled steel or other approved materials
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(b) be capable of withstanding the pressure test of the pipeline in which they are
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incorporated
(c) permit minimum angular deflection as shown below:
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Table 3.3 – Minimum Angular Deflection
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Pipe diameter (mm) Deflection

0
450 6
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0
450 – 600 5
0
600 – 750 4
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0
750 – 1200 3
0
1200 -1800 2
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0
>1800 1
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(d) be capable of accommodating a movement of 10 mm between ends of pipes they

connect.
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2 Adaptors and couplings shall be joined as recommended by the manufacturer.

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3 Where necessary to restrain movement at joints tied flange adaptors shall be used and the
deflection criteria shall not apply.
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4 All fasteners shall be stainless steel to BS970 Grade 316S31.
3.8.2 Flange Adapters
1 Flange adapters shall be used on PVC-U, GRP, cast and ductile iron, and joints between
each of the materials as designated. Flanges shall be PN 16 rating and gaskets shall be to
BS 3063.
3.8.3 Flexible Couplings
1 Flexible couplings shall be used with PVC-U, GRP, cast and ductile iron, and between joints
between pipes manufactured from each of the materials.
3.9 PIPES FOR OTHER USE
3.9.1 Copper Tubes and Fittings
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1 All tubes shall be clean, round, smooth and free from harmful defects and from deleterious
films in the bore. Copper tubing shall conform to BS EN 1057 and shall be half hard, light
gauge copper. Tubing shall be supplied in straight lengths by an approved manufacturer
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whose identification mark shall appear on each tube at about 0.5 m intervals. Approved
dielectric isolation fittings or attachments shall be furnished where copper fittings, piping or
tubing are connected to ferrous fittings or connections.
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2 Copper tubes for internal use shall be in accordance with Table X of BS EN 1057. Chromium
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plated copper tube shall be of plating quality in accordance with BS 1224, free of defects
such as blisters, pits, roughness, cracks or unplated areas. Fittings shall be of the
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compression type complying with BS 864 Part 2 and shall be resistant to dezincification.
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3 Copper tubes for external use shall be in accordance with Table Y of BS 2871 Part 1. Tubing
shall have a factory applied green coloured polythene sheath with a minimum thickness of
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1.0 mm. Fittings shall be of the compression or capillary type complying with BS 864 Part 2
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and shall be resistant to dezincification. Joints shall be adequately protected with tape to the
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3.9.2 Hose and Appurtenances

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1 Hose and hose reel shall be furnished for designated hose bibbs. Hose shall be 25 mm
diameter minimum and provided with an adjustable nozzle. Hose pipes for wash water shall
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be matched to the operating head of the supply system, be constructed for heavy duty and be
50m long. Hose pipes shall have a certified test pressure of 1.5 times the maximum
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operating pressure. Hose pipes for fire fighting shall be in accordance with Section 23.
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2 Couplings shall be furnished for each size hose, one for each 25 m length of hose provided;
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they shall be of cast brass quick fix type and shall have standard threads.
3.9.3 Stainless Steel Pipes, Tubes and Fittings

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1 All stainless steel for pipes, tubes and fittings shall be Type 316L.
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2 Stainless steel pipes and tubes shall conform to ASTM A312 and ASTM A688. Plate shall
conform to ASTM A240; diameters and wall thickness to ANSI B36.19.
3 Stainless steel fittings and specials shall be compression type conforming to ASTM A234.
Plate shall conform to ASTM A240; diameters, wall thickness and dimensions to ANSI
B36.19, ANSI B16.9.
4 Pipe sizes 50 mm and smaller shall be of Schedule 40 and above seamless stainless steel
with threaded ends, and shall conform to material specifications ASTM A312 and
dimensional specifications ANSI B36.19. Fittings shall be threaded, 2,000 pound forged
stainless steel, and shall conform to material specification ASTM A182 and dimensional
requirements of ANSI B16.11.
5 Unless otherwise designated, pipe sizes over 50 mm shall be Schedule 10 and above,
seamless stainless steel with bevelled ends for welding conforming to material specification
ASTM A312 and dimensional specification ANSI B36.19. Unless otherwise designated,
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fittings shall be Schedule 10, seamless stainless steel with bevelled ends for welding and
conform to material specification ASTM A403 and to the dimensional requirements of
ANSI B16.9 and ANSI B16.28. Flanges shall be ANSI slip-on or welding neck type, with
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150 pounds rating conforming to material specification ASTM A182 and to the dimensional
specifications ANSI B16.5.
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3.9.4 Carbon Steel Pipes and Fittings
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1 Carbon steel pipes shall conform to :
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2 ASTM A53, ASTM A106 for pipes, and ASTM A105 for fittings and flanges
3
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Carbon steel fittings and flanges shall conform to ASTM A105.
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3.10 MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES
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3.10.1 Applicable Standards

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1 MDPE and HDPE pipes shall conform to the latest editions of the following standards.
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EN ISO 527 ................Plastics -- Determination of tensile properties

EN ISO 1133-1 ...........Plastics. Determination of the melt mass-flow rate (MFR) and melt
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volume-flow rate (MVR) of thermoplastics.

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EN 1519 .....................Plastic piping systems for soil and waste discharge (low and high
temperature) within the building structure – Polyethylene (PE)
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EN ISO 1167 ..............Thermoplastic pipes, fittings and assemblies for the conveyance of
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fluids – Determination of the resistance to internal pressure

EN ISO 1183-2 ...........Plastics – Methods for determining the density of non-cellular plastics
– Part 2: Density gradient column method
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EN ISO 2505 ..............Thermoplastics pipes – Longitudinal reversion – Test method and

parameters
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EN ISO 3126 ..............Plastics piping systems – Plastic components – Determination of

dimensions
EN ISO 6259 ..............Thermoplastic pipes - Determination of tensile properties
EN ISO 9080 ..............Plastic piping and ducting systems – determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
EN 12099 ...................Plastics piping systems – Polyethylene piping materials and
components – Determination of volatile content
EN ISO 12162 ............Thermoplastic materials for pipes and fittings for pressure applications
- Classification and designation – Overall service (design) coefficient
EN 12201 ...................Plastic piping systems for water supply and for drainage and sewerage
under pressure – Polyethylene (PE)
EN 12666 ...................Plastic piping systems for non-pressure underground drainage and
sewerage – Polyethylene (PE)
EN ISO 13479 ............Polyolefin pipes for the conveyance of fluids. Determination of
resistance to crack propagation.
EN ISO 15512 ............Plastics – Determination of water content
EN ISO 16871 ............Plastics piping and ducting systems – Plastics pipes and fittings –
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Method for exposure to direct (natural) weathering
ISO 18553 ..................Method for the assessment of the degree of pigment or carbon black
dispersion in polyolefin pipes, fittings and compounds.
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ISO 4065 ....................Thermoplastic pipes – Universal wall thickness table
ISO 4427 ....................Plastics piping systems - Polyethylene (PE) pipes and fittings for water
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supply
ISO 6964 ....................Polyolefin pipes and fittings – Determination of carbon black content
by calcination and pyrolysis – Test method and basic specification
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ISO 9624 ....................Thermoplastic pipes for fluids under pressure – mating dimensions of
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flange adaptors and loose backing flanges
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ISO 11357-6 ...............Plastics – Differential scanning calorimetry (DSC) – Part 6:
Determination of oxidation induction time (OIT)
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ISO 11922-1 ...............Thermoplastic pipes for the conveyance of fluids – Dimensions and
tolerances - Part: 1: Metric series
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ISO 13761 ..................Plastics pipes and fittings – Pressure reduction factors for polyethylene
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pipeline systems for use at temperatures above 20ºC

ISO 13953 ..................PE pipes and fittings – Determination of tensile strength and failure
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mode of test pieces from a butt-fused joint

ISO 14236 ..................Plastics pipes and fittings – Mechanical joint compression fittings for
use with polyethylene pressure pipes in water supply systems
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ASTM D638-10...........Standard test method for tensile properties of plastics

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AWWA C224 ..............Standard for nylon-11 based polyamide coating system for the interior
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and exterior of steel water pipe, connections, fittings and special

sections
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WIS 4-24-01 ...............Specification for mechanical fittings and joints for polyethylene pipes
for nominal sizes 90 to 1000 mm OD
WIS 4-52-01 ...............Specification for polymeric anti-corrosion (barrier) coatings
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WIS 4-52-03 ...............Specification for anti-corrosion coatings on threaded fasteners

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3.10.2 Manufacture
1 MDPE and HDPE (PE) pipes and fittings shall be manufactured from virgin materials only.
Recycled, re-ground or re-generated materials shall not be used.
2 HDPE pressure pipes and fittings shall be manufactured from material conforming to polymer
classification PE100 having a minimum required strength value (MRS) of 10 MPa at 50 years
and 20ºC in accordance with ISO 4427. Design stress shall be 8 MPa. The pipe
manufacturer shall identify the manufacturer of the resin, the resin type and classification.
3 The HDPE pipe material shall be certified as meeting the requirements of the PE100+
Association.
4 HDPE pipes to be installed using trenchless technology applications shall be manufactured

from a PE100-RC material. Pipes manufactured from such material shall have undergone the
Notched Pipe Test at an independent 3rd party laboratory in accordance with ISO 13479 and
the time to failure shall have been a minimum of 8,760 hours (1 year). All other
characteristics shall comply with the PE100 requirements of ISO 4427 and this specification.
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5 HDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
the Engineer and shall have a pressure rating of 16 bar (PN16) at 20ºC (de-rated to 11.8 bar
at 40ºC, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by the
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Engineer.
6 Pipes and fittings shall be designed to achieve a minimum working life of 50 years under all
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applicable loads, environmental and installation conditions.
7 MDPE pressure pipes and fittings shall be manufactured from material conforming to
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polymer classification PE80 having a minimum required strength value (MRS) of 8 MPa at 50
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years and 20ºC in accordance with ISO 4427. Design stress shall be 6.4 MPa. The pipe
manufacturer shall identify the manufacturer of the resin, the resin type and classification.
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8 MDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
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the Engineer and shall have a pressure rating of 12.8 bar (PN12.8) at 20ºC (de-rated to 9.5
bar at 40ºC, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by
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the Engineer.
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9 Pipes and fittings shall be homogeneous throughout and free of visible cracks, holes, foreign
inclusions, voids and other injurious defects.
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10 The resin from which the pipes and fittings are manufactured shall comply with the
requirements of ISO 4427 Part 1 and be protected from UV attack by the addition of carbon
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black in accordance with the standard.

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11 Straight lengths of PE pipe shall be supplied in standard lengths of 12m (-0/+50 mm)
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measured at 23°C ± 2°C. Unless otherwise specified, coil length shall not exceed 100m.
Coiled pipes shall be coiled such that localised deformation is avoided and the minimum
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internal diameter of the coil shall not be less than 20 x outside diameter. Prior to jointing the
degree of pipe ovality shall not exceed the permissible levels given in Table 1 of ISO 4427,
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Part 2 and the Contractor shall, if required, use mechanical re-rounding equipment to meet
these requirements. Field cut lengths of pipe used as closures may not be shorter than 0.75
metre in length and shall be approved by the Engineer.
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12 All pipes shall be indelibly marked at intervals of maximum 1m. The colour of the pipe
marking shall always contrast with the colour of the pipe. Markings shall include the following
information:
(a) Manufacturer’s name, trademark

(b) Material and designation i.e. PE100
(c) The nominal pressure (PN) of the pipe / fitting
(d) Dimension of the pipe (nominal outside diameter x nominal wall thickness)
(e) Standard Dimension Ratio (SDR)

(f) Production period (date / batch code)
(g) International Standard to which the pipe / fitting has been produced to
(h) Designation of the medium for which the pipe is produced for (water, gas, sewage)
(i) Stencilled in legible letters the pipe identification number on the outside at each end.
Ensure that the same number appears on all record sheets and documents relating to
the manufacture, delivery and testing of that pipe.
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13 Pipes shall be delivered in wooden frames or similar arrangement to avoid movement
between pipes. Pipes shall not be stacked higher than 1m in each frame or packing
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arrangement.
3.10.3 Fittings
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1 Unless otherwise specifically approved by the Engineer, all PE pressure pipe fittings for use
with pipes of up to 355 mm OD shall be injection moulded with the same polymer
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classification, material type and pressure rating as the pipe to which they are to be
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connected. All joints between PE pipes and fittings shall whenever possible be by thermal
butt fusion welding or electro-fusion welding process.
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2 Connections of PE pipes and fittings to metallic fittings shall be made with PN16 backing
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rings with a stainless steel stiffener insert or as recommended by the pipe or fitting
manufacturer and approved by the Engineer.
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3 Transition fittings used to join the pipe to flanged fittings and pipes made of other materials
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shall be certified by an independent third party as being fully compliant with the Type 1 or
Type 2 requirement of WIS 4-24-01 i.e. they shall prevent the pull out of the pipe at their
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rated operational and test pressures.
4 Metallic fittings shall be fully coated to provide protection against corrosion. The coating shall
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be a factory applied fusion bonded epoxy or a nylon 11 based polyamide coating system,
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have a minimum dry film thickness of 250 microns and comply with the requirements of
either AWWA C224 or WIS 4-52-01. Any bolts, studs or nuts shall be of stainless steel
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(grade 304 or better) or else be protected with a coating that complies with the requirements
of WIS 4-53-03. All buried metallic fittings shall be protected by petroleum impregnated
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primer, paste and tape prior to back filling.
5 Where their use is approved by the Engineer, all compression fittings shall be certified by an
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independent third party as being fully compliant with the requirements of ISO 14236. They
shall be tested and certified as being class 1 end load bearing fittings i.e. they shall prevent
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the pull out of the pipe at their rated operational pressure. Only materials listed in Tables 1
and 2 of ISO 14236 shall be used in the manufacture of the fitting body.
6 Where the use of fabricated fittings has been specifically approved by the Engineer such
fittings shall be designed and manufactured in accordance with the requirements of ISO
4427, Part 3, in particular Annex B. The pressure derating factors to be employed by the
fittings fabricator shall be in accordance with annex sections B3 and B5 unless they can
demonstrate that higher factors can be applied. The use of any higher factors shall be
approved by the Engineer prior to commencement of fitting fabrication.
7 All PE fittings shall, as a minimum, be indelibly marked with the following information:
(a) Manufacturer’s name, trademark

(b) International Standard to which the pipe / fitting has been produced to
(c) Material and designation i.e. PE100
(d) The nominal pressure (PN) of the pipe / fitting
(e) Outside diameter and Standard Dimension Ratio (SDR)
(f) Production period (date / batch code)
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8 PE Fittings shall be individually packed in bulk, bag or individual protection against
contamination. Electrofusion fittings shall always be packed in a sealed bag or container. The
packaging shall, as a minimum, be labelled with the manufacturer’s name, quantity, type and
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dimension.
3.10.4 Pipes and Fittings for Gravity Applications
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1 Pipes and fittings for drainage applications shall be suitable for carrying potable water,
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treated sewage effluent, raw sewage and surface water at temperatures up to 40ºC as
dictated by the particular application and they shall comply with the requirements of EN1519
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or EN 12666, as appropriate.
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3.10.5 Testing of MDPE and HDPE Pressure Pipes and Fittings
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1 The raw material and pipe manufacturers shall document and certify all products and shall
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undertake all testing required by ISO 4427 and this specification.
2 Prior to delivery of any pipes or fittings the pipe manufacturer shall provide the Engineer with
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a comprehensive Inspection and Testing Plan (ITP) for their approval. The ITP shall detail all
the certificates and documents that shall be provided by the pipe manufacturer, together with
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details of the testing that they shall undertake, its frequency and associated test reports.
Where the pipe manufacturer cannot themselves undertake the required testing they shall
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employ an independent third party laboratory to undertake the testing on their behalf.
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3 Definition of material, pipe and fittings batches for the purposes of batch release testing:
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(a) A raw material batch shall be considered as a batch of material supplied by the resin
producer having an individual identification number or code. For the purposes of this
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specification it shall also be the raw material used to manufacture a particular pipe
batch.
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(b) A pipe batch shall be considered as a continuous production run of a particular pipe
OD and wall thickness manufactured from one resin type with no change in the
manufacturing process.
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(c) A batch of fabricated fittings shall be considered as group of fittings of the same OD
and wall thickness.
4 The pipe manufacturer shall undertake the following minimum batch release testing.
Table 1 –Release tests to be undertaken on each raw material batch
Sampling No. of Tests or

Characteristics Reference
Frequency Inspections
Once per raw

Compound Density ISO 4427-1 section 4 1
material batch
Once per raw
Oxidation induction time ISO 4427-1 section 4 1
material batch
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Once per raw
Melt mass-flow rate ISO 4427-1 section 4 1
material batch
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Table 2 – Release inspections and tests to be undertaken on each batch of pipes
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Characteristics Reference Sampling No. of Tests or
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Frequency Inspections
Appearance and colour ISO 4427-2 section 5 M Continuously -
Geometrical ISO 4427-2 section 6 Continuously -

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Marking This specification Each pipe or coil 1

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Melt mass-flow rate ISO 4427-2 section 8 Once per pipe batch 1
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Elongation at break ISO 4427-2 section 8 Once per pipe batch 1

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Tensile strength at yield on a ISO 6259 (Tensile Once per pipe batch 1
sample cut from HDPE pipe strength to be ≥ 19MPa)
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Tensile strength at yield on a ISO 6259 (Tensile Once per pipe batch 1
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sample cut from MDPE pipe strength to be ≥ 15MPa)

Longitudinal reversion ISO 4427-2 section 8 Once per pipe batch 1
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Pipe wall thickness shall be measured and controlled on a continuous basis using and ultrasonic
thickness gauge or similar device that shall be regularly calibrated in accordance with the gauge
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manufacturer’s recommendations.
5 In accordance with the recommendations of ASTM D 638, the maximum thickness of the
tensile strength test samples cut from the pipe wall shall be 14 mm. In the event of the pipe
wall being thicker than 14 mm the pipe manufacturer shall machine the test samples in
accordance with the Table 3.
Table 3 – Preparation of samples for tensile testing

Pipe Wall Thickness (WT) Test Sample Thickness No. of samples to be
(mm) (mm) taken from the pipe wall
≤ 14 WT 1
14 < WT ≤ 28 WT/2 2
28 < WT ≤ 42 WT/3 3
42 < WT ≤ 56 WT/4 4
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56 < WT ≤ 72 WT/5 5
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All testing shall be undertaken in accordance with ISO 6259 and all HDPE samples shall
achieve a minimum tensile strength at yield of 19 MPa in order for the pipe to successfully
pass the test. MDPE samples shall have achieved minimum tensile yield strength at yield of
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15 MPa.
Table 4 – Release inspections and tests to be undertaken on each batch of fabricated fittings
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ID
Characteristics Reference Sampling No. of Tests or
M Frequency Inspections
Appearance and colour ISO 4427-2 section 5 Continuously -
Geometrical ISO 4427-2 section 6 Continuously -

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Marking This specification Each fitting 1

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Hydrostatic strength at 20 C, ISO 4427-3 Annex B Once per batch of 1 piece only
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100hrs & 12.4MPa x ƒ HDPE fittings

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Hydrostatic strength at 20 C, ISO 4427-3 Annex B Once per batch of 1 piece only
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100hrs & 10 MPa x ƒ MDPE fittings
The fabricated fitting to be hydrostatically tested shall be a tee or branch provided the batch
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in question contains this type of fitting, otherwise a bend shall be tested.

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6 In the case of injection moulded fittings the manufacturer shall issue a certificate confirming
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compliance with ISO 4427 and providing details of the type testing undertaken by an
independent third party in accordance with sections 7 and 8 of ISO 4427 – Part 3.
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7 The pipe manufacturer shall provide the Engineer with a copy of the batch release tests i.e.
all those tests listed above, with each batch of pipes or fittings that is delivered to site.
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8 Prior to delivery of pipes the pipe manufacturer shall provide the Engineer with copies of all
the test results and certification required by ISO 4427, this specification and the ITP, but
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which are not covered by the above batch testing requirements. These documents shall
comprise the Type Test Report.
9 The Type Test Report shall include a copy of the raw material manufacturer's "Certificate of
Quality Control Testing" covering each batch of raw material used for manufacturing pipes
produced under this specification.
10 The pipe manufacturer shall ensure that all the applicable codes and standards are available
at their facility for the Engineer’s reference during any visit or inspection.
11 The pipe manufacturer shall provide full assistance and co-operation for any inspection,
when required by the Engineer or by an inspector appointed by the Engineer.
12 The Engineer may reject any item that does not successfully pass the required tests or fully
comply with the requirements of this specification. When a pipe or fitting is rejected, the items
manufactured immediately before or after shall be carefully examined and tested at the
direction of the Engineer. If further defects are found, the entire batch shall be rejected.
13 All pipes and fittings shall be visually inspected by the PE Welding Inspector before
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incorporation in the Works.
14 In addition to those tests specifically required, the Engineer may request additional samples
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of any material for testing by the Engineer and all expenses incurred in obtaining samples for
testing shall be borne by the Contractor at no additional cost to the Contract.
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3.11 POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-
PRESSURE DRAINAGE AND SEWERAGE
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3.11.1 General
1
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Polyester resin concrete is a mixture formed from aggregates and fillers which are bound
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together using a polyester resin (also called Polymer concrete pipes), as defined in ISO
18672-1 or ASTM D 6783 with the amendments given below.
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2 Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems
(pipes, manhalls, soakways).
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3.11.2 Resin
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1 The resin used in the pipe system and manufactured as per ISO 18672-1shall have a
temperature of deflection of at least 85 °C, when tested in accordance with Method A of
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ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the
applicable requirements of EN 13121-1.
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2 The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a
minimum deflection temperature of 85°C when tested at 1.82 MPa following Test Method
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D648. The resin content shall not be less than 7% of the weight of the sample as determine
by test method D2584
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3.11.3 Minimum strength
1 The minimum strength classes for different pipe shapes are given below
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Table 3.11.1
Minimum strength classes for pipes designated PRC-OC or PRC-TC
Strength class
Nominal size Sc
DN N/mm
PRC-OC PRC-TC
150 ≤ DN ≤ 500 180 180
600 ≤ DN ≤ 1000 145 160
1200 ≤ DN≤ 3000 120 145
Table 3.11.2
Minimum strength classes for pipes designated PRC-OE or PRC-TE
Strength class
Nominal width/height Sc
WN/HN
N/mm
PRC-OE PRC-TE
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300/450 ≤ WN/HN ≤ 600/900 180 180
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700/1050 ≤ WN/HN ≤ 1000/1500 145 160
1200/1800 ≤ WN/HN ≤ 1400/2100 120 145
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Table 3.11.3
— Minimum strength classes for pipes designated PRC-OK or PRC-TK
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Strength class
Sc
Nominal size
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DN N/mm
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PRC-OK PRC-TK
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800 ≤ DN ≤ 1000 145 160

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1200 ≤ DN ≤ 1800 120 145

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END OF PART
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Part 04: Pipeline Installation
4 PIPELINE INSTALLATION ............................................................................ 3
4.1 GENERAL ...................................................................................................... 3

4.1.1 Scope of Work 3
4.1.2 References 3
4.1.3 Guidelines 4
4.1.4 Definitions 4
4.1.5 Submittals 4
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4.1.7 Delivery, Storage and Handling 5
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4.1.8 Specialists, Inspection and Testing 5
4.1.9 Soil Corrosivity Study 6
4.1.10 Setting Out and Pipeline Alignment 6
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4.1.11 Tools for Installation and Testing 6
4.1.12 Inspection During Installation 6
4.1.13 Dewatering 7
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4.1.14 Closures and Short Sections 7
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4.1.15 Cutting of Pipes 7
4.1.16 Stringing of Pipes 7
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4.1.17 Inspection of Trench Formation 8
4.1.18 Overpumping and Flow Diversions 8
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4.1.19 Other Services 8

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4.2 DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND

GRP PIPELINE JOINTING ............................................................................ 8
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4.2.1 Push-fit Joints 8

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4.2.2 Mechanical Joints 9

4.2.3 Flanged Joints 9
4.2.4 GRP Joints 9
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4.3 MDPE AND HDPE PIPELINE JOINTING .................................................... 10

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4.3.1 General 10
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4.3.2 PE Welding Technicians 10

4.3.3 PE Welding Inspectors 10
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4.3.4 PE Welding Equipment 11

4.3.5 Method Statements 11
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4.3.6 Electrofusion Jointing 11

4.3.7 Electro-fusion Joint Inspection 12
4.3.8 Butt Fusion Jointing 12
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4.3.9 Butt Fusion Joint Inspection 13

4.3.10 Testing of Fusion Joints 13
4.3.11 Anchorage 13
4.4 PIPE LAYING .............................................................................................. 14
4.4.1 General 14
4.4.2 Laying of Rigid and Semi-Rigid Pipes 15
4.4.3 Laying of Flexible MDPE and HDPE Pipes 16
4.4.4 Laying of GRP Pipes 16
4.4.5 Corrosion Protection of Ferrous Pipelines 18
4.4.6 Concrete Protection to Pipe 19

4.4.7 Deflection Criteria for Flexible Pipelines 20
4.4.8 Backfilling 20
4.4.9 Deflection at Joints 21
4.4.10 Wadi Crossings 21
4.4.11 Pipe Supports 22
4.4.12 Building-in Pipes to Structures 22
4.4.13 Cleanliness of Pipelines 23
4.4.14 Marker Tape 24
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4.4.15 Pressure Pipeline Marker Posts 24
4.4.16 Valve Chamber Marker Posts 24
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4.4.17 Abandonment of Pipelines 24
4.4.18 Abandonment of Structures 25
4.4.19 Corrosion Protection of Flexible Couplings and Ferrous Fittings 25
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4.5 PIPELINE STRUCTURES AND APPURTENANCES .................................. 26
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4.5.1 Manholes for Foul Sewerage 26
4.5.2 Manholes for Surface Water Sewerage 28
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4.5.3 Chambers 28
4.5.4 Connections to Existing Pipelines 28
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4.5.5 Anchor and Thrust Blocks 29
4.5.6 Property Connections Survey 29
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4.5.7 Future House Connections 29

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4.6 TESTING OF PIPELINES ............................................................................ 30

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4.6.1 General 30
4.6.2 Gravity Sewer Pipelines 31
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4.6.3 Pressure Pipelines 32

4.6.4 Other Pressure Pipelines 33
4.6.5 MDPE and HDPE Pressure Pipelines 34
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4.7 MISCELLANEOUS ITEMS .......................................................................... 38

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4.7.1 Manhole Covers and Frames 38

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4.1.2 Duct Covers and Frames 39

4.7.2 Hinged Aluminium Access Covers 40
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4.8 FUTURE SEWER CONNECTION ............................................................... 40

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4.8.1 General 40
4.9 INSITU LINING OF EXISTING MANHOLES ............................................... 41
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4.9.1 General 41
4 PIPELINE INSTALLATION
4.1 GENERAL
4.1.1 Scope of Work
1 This Part includes the installation of pipelines.
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This Section
Part 1, General
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Part 2, Earthworks
Part 3, Pipes and Fittings Materials
Part 5, Valves, Penstocks and Appurtenances
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Part 6, Miscellaneous Metal Works
Part 7, Miscellaneous GRP Works
Part 8, Protective Coatings and Painting
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ID
Section 1, General
Section 2, Demolition and Alterations M
Section 3, Ground Investigation
Section 5, Concrete.
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4.1.2 References
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1 The following standards are referred to in this Part:

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BS EN 12620..............Aggregates from natural sources for concrete

BS 4872......................Approval testing of welders when welding procedure approval is not
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required
BS 6072......................Tubular polyethylene film for use as a protective sleeving for buried
iron pipes and fittings
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BS EN 752..................Drain and sewer systems outside buildings

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BS EN 1092................Flanges and their joints

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BS EN 12007..............Gas supply systems - Pipelines for maximum operating pressure up to

and including 16 bar, Part 2: Specific functional recommendations for
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PE
ISO 12176 ..................Plastics pipes and fittings — Equipment for fusion jointing polyethylene
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systems, Parts 1 and 2

ISO 21307 ..................Plastics pipes and fittings — Butt fusion jointing procedures for
polyethylene (PE) pipes and fittings used in the construction of gas
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and water distribution systems

ISO 13953 ..................Polyethylene (PE) pipes and fittings - Determination of the tensile
strength and failure mode of test pieces from a butt fused joint
ISO 13954 ..................Plastics pipes and fittings - Peel decohesion test for polyethylene (PE)
electrofusion assemblies of nominal outside diameter greater than or
equal to 90 mm
SFS 3115:E ................Plastics Pipes Water Tightness Test for Pressure Pipelines (English
version of Finnish Standard)
WIS-4-08-02 ...............Specification for bedding and sidefill materials for buried pipelines
AWWA C200 ..............Steel Water Pipe 150 mm and Larger

AWWA C600 ..............Installation of Ductile-Iron Water Mains and Their Appurtenances.
4.1.3 Guidelines
1 The following Guidelines are applicable to the installation and testing of HDPE pipes and
fittings:
DVGW GW330...........Installation & Welding of High Density Polyethylene (HDPE) Pipes for
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Gas & Water Applications
DVGW GW331...........Supervision of Installation & Welding of High Density Polyethylene
(HDPE) Pipes for Gas & Water Applications
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DVS 2202-1 ................Imperfections in thermoplastic welded joints: Features, description,
evaluation
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DVS 2203-1 ................Testing of welded joints of thermoplastic sheets and pipes: Test
methods – Requirements
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DVS 2207-1 ................Welding of thermoplastics: Heated tool welding of pipes, pipeline
components and sheets made of HDPE
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DVS 2208-1 ................Welding of thermoplastics: Machines and devises for the heated tool
welding of pipes, pipe parts and panels
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4.1.4 Definitions
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1 Pipes: circular tubes through which fluid can flow including manufactured lengths of pipes,
bends, fittings, junctions and other specials, joints and jointing parts.
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2 Valves: manufactured devices for controlling the passage of fluids through pipes including
sluice gates, reflux valves, and air valves including associated joints, jointing parts, operating
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gear and fittings.
3 Installation: material transport and handling, pipelaying including the complete operation of
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laying jointing and testing pipes in trenches or elsewhere, and the construction of pipeline
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ancillaries
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4 Pipeline: long, continuous line of pipes and fittings including valves and ancillary structures
and equipment used for transporting fluids; specifically, sewers and ancillary works for the
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transport of sewage and surface water and similar pipelines for the transport of treated
sewage effluent.
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4.1.5 Submittals
1 The Contractor shall submit the documents described in the following paragraphs.
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2 Working drawings: Before commencing work the Contractor shall prepare working drawings
necessary for the construction and installation of facilities. The drawings shall be prepared to
A1 size or a size and scale as directed by the Engineer. The drawings shall be submitted to
the Engineer in an orderly manner and at periods which will permit adequate time for review
and approval by the Engineer. Five copies of drawings shall be submitted.
3 Detailed work programme with schedule for the delivery of pipes and fittings
4 Methods statements to supplement the working drawings, as follows:
(a) installation
(i) joints and couplings
(ii) measures to ensure integrity of interior pipe lining and exterior protective
coating at joints and couplings
(iii) installation and adjustment of pipe bedding and other supports
(iv) fitting of pipelines to valves.
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(b) testing of sewer pipelines and pressure pipelines to the requirements described
in Subpart 4.5
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(c) welding procedures and electrodes with drawings and schedules as may be
necessary
(d) safety procedures and protective equipment
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5 Quality assurance and control documents including
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(a) certified copies of reports of required tests including:
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(i) pipe pressure tests M
(ii) dielectric joint tests
(b) copies of certificates relating to welder’s tests shall be made available to the
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Engineers on request
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1 A suitably qualified and experienced safety officer shall be employed to ensure that all
Contractor’s employees follow safety procedures and are provided with appropriate safety
and protective equipment.
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2 Welders employed on the fabrication and site welding shall have passed the welder approval
tests of BS 4872, Part 1 or other standard approved by the Engineer.
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4.1.7 Delivery, Storage and Handling

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1 Delivery, storage, and handling shall be as specified in Part 3 of this Section.

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2 The Contractor shall replace or repair pipe damaged during handling and installation, to the
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4.1.8 Specialists, Inspection and Testing
1 The Employer may employ the services of a specialist firm to assist the Engineer as he may
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require in any matter connected with pipes, and fitting including the inspection of materials
and workmanship and the witnessing of tests at any stage during the execution and
maintenance of the Works.
2 Such independent tests may be carried out at any stage during the execution and
maintenance of the Works, but they shall not relieve the Contractor of his obligations under
the Contract.
3 To the extent ordered by the Engineer, the Contractor shall provide labour, plant, tools and
materials (but not special testing equipment) for direct assistance to the specialist firm in their
inspection and independent testing and for any further work, investigations, and repairs which
the Engineer considers necessary as a result of such inspection or testing.
4 The provision of labour, plant and materials as aforesaid shall be an obligation of the
Contractor where in the Engineer's opinion the inspection test or further investigation shows
that materials and workmanship provided by the Contractor do not comply with the
designated requirements.
4.1.9 Soil Corrosivity Study
1 Where designated in the Project Specification, the Contractor shall carry out a soil corrosivity
study along the route of proposed ferrous pipelines as directed by the Engineer and mark the
results on the pipeline layout plans.
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2 Soil resistivities shall be undertaken using a low resistance, null-balance earth tester and a
four pin array, or any other equipment approved by the Engineer. Readings shall be
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recorded in ohm-cm and shall be taken at 1.0 m incremental depths to a depth 1 m below the
pipeline invert levels. Readings shall be taken at a spacing along the route of the proposed
pipelines as required to reflect the changing soil conditions, but in no case shall the spacing
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exceed 500 m.
3 Soil samples shall be taken as directed by the Engineer along the route of the proposed
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pipelines at a maximum spacing of 500 m. Soil samples shall be tested for sulphates,
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sulphides, chlorides, pH, moisture content, and carbonates.
4.1.10 Setting Out and Pipeline Alignment

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1 All sewers shall be laid accurately to the lines, and levels gradients shown on the approved
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drawings so that the pipeline is straight between successive manholes in the vertical and
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horizontal planes.
2 Pressure pipelines shall be laid accurately to the lines levels and depths shown on the
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approved drawings. Where changes of direction are required, deflections shall be made in
accordance with the manufacturer’s recommendations.
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3 Manufactured bends shall only be used where shown on the Drawings or where otherwise
permitted by the Engineer’s Representative.
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4 Where pipelines of constant gradient are to be laid, the Contractor shall provide, fix and
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maintain at such points as may be directed by the Engineer’s Representative properly

painted sight rails and boning rods of pre-determined measurement for the boning in of
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individual pipes to correct alignment. The sight rails shall be situated vertically over the line of
pipes or immediately adjacent thereto and there shall at no time be less than three sight rails
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in position on each length of pipeline under construction to any one gradient
5 If the Contractor wishes to propose an alternative method of controlling pipeline alignment,

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he shall submit his proposed method to the Engineer’s Representative for approval
4.1.11 Tools for Installation and Testing

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1 The Contractor shall supply all necessary tools for cutting, chamfering, jointing, testing and
for any other requirement for satisfactory installing the pipelines.
4.1.12 Inspection During Installation
1 Pipes and fittings including any sheathing, inside linings and outside coatings, shall be
inspected by the Contractor immediately before and after installation, and damage or other
imperfection shall be repaired by the Contractor as directed by the Engineer before
installation and in accordance with the following:
(a) Material required for the repair of pipe, sheathing, linings and coatings shall be
obtained by the Contractor and shall be used in accordance with the manufacturers
recommendations.
(b) Without relieving the Contractor of any of his obligations, the Engineer may inspect
and test the pipe and appurtenances by any appropriate means, and damage
discovered by such inspection shall be repaired by the Contractor.
(c) The Contractor shall remove from Site any pipe or appurtenance which in the
opinion of the Engineer is so damaged as to be unfit for incorporation in the Works.
The obtaining of replacements for damaged pipes and fittings to the approval of the
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Engineer shall be an obligation of the Contractor.
4.1.13 Dewatering
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1 All pipeline installation work shall be carried out in the dry.
2 Dewatering shall be carried out as specified in Part 2 of this Section.
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4.1.14 Closures and Short Sections
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1 For the purpose of reducing the angular deflections at pipe joints, and for closure sections,
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the Contractor will be permitted to install pipe sections of less than standard length. Closing
lengths and short sections of pipes of all types shall be fabricated and installed by the
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Contractor as found necessary at Site. Where closing pieces are required, the Contractor
shall make all necessary measurements and shall be responsible for the correctness thereof.
The Contractor shall be responsible for taking the measurements required to determine the
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lengths of cut portions of pipes for insertion as closing lengths in pipelines.
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4.1.15 Cutting of Pipes

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1 Where pipes are required to be cut on the Site the cutting shall be done by the Contractor in
accordance with the manufacturer’s recommendations and in a manner approved by the
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Engineer.
2 The pipe and methods of jointing shall be such that the locations of fittings and lengths of
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pipe can be adjusted to suit Site conditions.

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3 Cutting of reinforced concrete pipes will not be allowed. Special lengths of pipes shall be
manufactured for closures as required. Other pipes such as GRP, ductile iron, vitrified clay,
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MDPE, HDPE, PVC-U and cast iron pipes shall only be cut if approved by the Engineer.
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4 The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes for inserting
specials, fittings or closure pieces shall be carried out as follows:
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(a) Cutting shall be carried out in a neat and workmanlike manner with an approved
cutting machine without damage to the pipe and so as to leave a smooth end at right
angles to the axis of the pipe.
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(b) Cutting by hacksaw shall not be permitted unless approved by the Engineer.
(c) Only experienced men shall be employed by the Contractor on this work.
(d) The Contractor shall take every precaution to ensure that both the measurement
tolerances and the cutting of pipes are to the accuracy required. Should any errors
occur the Contractor shall correct the defects to the approval of the Engineer.
4.1.16 Stringing of Pipes
1 Pipes shall be distributed to installation site only in such quantities as can be installed in one
working day or as allowed by the Engineer.
2 The Contractor shall take pipes from the storage areas, unload and string along the route of
the proposed pipeline. Pipes shall be so strung as to cause the least practicable interference
with the use of the land.
3 After a pipe has been strung and immediately before being laid, it shall be cleaned out and
inspected for defects. Cast or ductile iron pipes shall be rung with a light hammer while the
pipe is suspended clear of the ground to detect cracks. Other pipes shall be visually
inspected. Any defective, damaged or unsound pipe shall be rejected. Any damage to the
lining or coating of the pipe shall be repaired or the pipe rejected as directed by the Engineer.
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4 Plastic pipes shall not be strung along the pipe route but shall be stored in accordance with
Part 3 of this Section until required for laying and jointing.
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4.1.17 Inspection of Trench Formation
1 After excavations have been completed to the designated levels and, trench formation
compacted, the Contractor shall issue a formal notice to the Engineer that the trench
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formation is ready between designated points for inspection. The Engineer will without
unreasonable delay inspect the said trench formation, unless he considers it unnecessary
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and advises the Contractor accordingly. Any rejection of trench formation will be confirmed in
writing by the Engineer.
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2 The formation will be re-inspected by the Engineer after replacement of any unsound material
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with material as specified under Clause 2.2.3 of Part 2 of Section 8.
3 No bedding shall be placed until the Engineer’s Representative has given his approval to the
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trench formation.
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4.1.18 Overpumping and Flow Diversions

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1 Flow diversions shall be in accordance with Clause 10.4 of the Section.

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4.1.19 Other Services
1 Where the Works requires the seeking, protection, diversion or relocation of existing services
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the procedures set out in Section 6 Part 11 shall be followed.

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4.2 DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND GRP
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PIPELINE JOINTING
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4.2.1 Push-fit Joints
1 Immediately before assembling each joint incorporating a rubber ring seal, the rubber shall
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be inspected for cracks, every part of the ring being deformed by hand to about 150 mm
radius. If under this deformation any cracks are either revealed or initiated then the ring shall
be rejected, cut through completely to prevent inadvertent use, and the matter reported
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forthwith to the Engineer. If more than three successive rings inspected in this way are
rejected the Contractor shall on the instruction of the Engineer stop all pipe jointing until the
cause of the defect has been proved and remedied to his satisfaction.
2 The rubber ring shall be placed in the groove on the socket or spigot ring. The groove shall
be free of deleterious material; e.g., dirt, moisture, oil, and grease. The inside surface of the
socket shall be lubricated with a compound recommended by the manufacturer which will
facilitate the telescoping of the joint. The spigot end of the pipe shall then be inserted into the
socket of the adjoining pipe using a suitable tool to push the spigot into the socket. The
position of the pipe and the gasket in the joint shall then be checked using a feeler gauge to
demonstrate proper jointing. When joints are not properly made, pipes shall be adjusted, or
removed and rejointed as necessary to ensure proper jointing. Care shall be taken to avoid
twisting or cutting the ring when jointing the pipe.
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3 For pipes up to and including 700 millimetres nominal bore the joints shall be capable of
withstanding a deflection of not less than 1.5 degrees in any direction and for pipes over 700
millimetres nominal bore 0.5 degrees in any direction. All pipe joints shall be capable of
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withstanding a “draw” of 13 millimetres over and above the initial jointing allowance. The
initial jointing allowance is the gap between the spigot and the shoulder of socket measured
parallel to the centre line of the pipeline and shall not be less than 6 millimetres or greater
than 13 millimetres.
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4.2.2 Mechanical Joints
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1 Where mechanical joints are approved, installation shall be in accordance with the
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manufacturer’s recommendations. The Contractor shall render the end of each pipe perfectly
smooth so as to allow the joint sleeve to slide freely and where necessary shall coat the pipe
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ends with two coats of an approved quick drying sealing and protective compound. Buried
joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied as
clause 4.3.5.
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IN
4.2.3 Flanged Joints
1 Flanged joints for ductile iron and cast iron pipes and specials shall be made with rubber joint
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gaskets and steel bolts and nuts which shall include two washers per bolt. The use of jointing
paste or grease shall not be permitted. The gasket may be fastened to the bolts with cotton
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thread. The bores of abutting pipes or fittings shall be concentric and no jointing material is
to be left protruding into the bore.
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2 All nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference
shall then be alternately and progressively tightened with a spanner so as to ensure even
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pressure all around the joint.

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3 Buried joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied
as clause 4.3.5.
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4.2.4 GRP Joints

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1 Joints shall be of the “O” ring or rolling type, and shall incorporate a soft or flexible control
register to help to locate the joint.
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2 GRP pipe joints shall be assembled in accordance with manufacturer's instructions for the
type of flexible joint provided.
3 Joints shall be capable of withstanding the various tests specified for the appropriate class of
pipe. Joints shall withstand, while maintaining the specified test pressure, a deflection of not
less than 1.5  in any direction or for pipes up to and including 600 mm nominal bore, and
0.5  in any direction for pipes over 600 mm diameter.
4 Rubber joint rings shall be made of EPDM SBR or nitrile rubber (NBR) and shall comply with
the relevant requirements of BS EN 681-1 for Type WG rings.
5 Flanged pipes, if required, shall incorporate an annular gasket and these gaskets shall cover
the full face of the flange and shall have holes cut in correspondence to the bolt holes in the
flanges. Flanges shall be drilled to BS EN 1092 type PN 16. Alternatively jointing system for
flanged pipes, incorporating rubber rings, may be approved by the Engineer. Stainless steel
backing rings shall be inserted between the bolt head / nut and the GRP flange to spread the
load.
4.3 MDPE AND HDPE PIPELINE JOINTING
4.3.1 General
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1 The Contractor shall abide by the following guidelines with regards to jointing MDPE and
HDPE (PE) pipes and fittings unless otherwise approved by the Engineer.
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(a) PE pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever
possible.
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(b) PE pipes and fittings of less than 90 mm OD shall be joined together using electro-
fusion couplings and fittings.
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(c) Electro-fusion fittings may also be used to undertake repairs and install off-takes or
connections on existing pipelines. They may also be used for the joining together of
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pipe strings where it is not practical to use a butt fusion welding machine.
(d) To join PE pipes to metal pipes and fittings such as valves, restrained mechanical
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transition fittings and stub flanges shall be used.
(e) Restrained mechanical fittings may, with the permission of the Engineer, to undertake
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repairs and install off-takes or connections on existing pipelines.

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4.3.2 PE Welding Technicians

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1 All PE electro and butt fusion jointing, PE jointing to GRP and metallic valves and fittings shall
only be undertaken by a certified HDPE Welding Technician holding a valid Welder Licence.
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2 The PE Welding Technician shall have attended a comprehensive course on the Installation
and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
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be 5 days and the Technician shall have sat and passed an exam in accordance with the
GW330 standard of the German Technical and Scientific Association for Gas and Water
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(DVGW) or an equivalent national body approved by the Engineer.

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3 The PE Welding Technician shall hold a valid GW330 Welder License or equivalent issued
by a national body approved by the Engineer, which shall be subject to annual renewal by
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attending a re-examination course.
4.3.3 PE Welding Inspectors

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1 A specialist PE Welding Inspector shall observe and supervise the handling, welding, jointing
to other materials and testing on site of all HDPE pipes and fittings.
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2 The PE Welding Inspector shall have attended a comprehensive course on the Installation
and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
be 5 days and the Inspector shall have sat and passed an exam in accordance with the
GW331 standard of the German Technical and Scientific Association for Gas and Water
(DVGW) or an equivalent national body approved by the Engineer.
4.3.4 PE Welding Equipment
1 All welding machines and welding equipment shall fulfil the requirements of DVS 2208-1 or
the relevant part of ISO 12176. All welding machines shall be of an automatic or semi-
automatic design where the welding machine determines and controls the welding
parameters based on the pipe and fitting details entered by the operator. They shall also be
equipped with a data logging function that measures and records information listed in DVS
2208-1.
2 All machines shall undergo a yearly calibration and function test, carried out by a service
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centre authorised by the machine manufacturer.
4.3.5 Method Statements
EA
1 A detailed method statement for PE pipe jointing shall be prepared by the Contractor and
submitted to the Engineer for approval. The method statement shall include details of which
equipment shall be used and how the work will be performed to ensure compliance with the
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recommendations of the pipe manufacturer and of this specification. It shall include, but not
be limited to:
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(a) Details of the equipment to be employed by the Contractor, together with procedures
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for its operation, maintenance, periodic inspection and testing.
(b) Details of the experience and certification of the pipe and fitting jointers that shall be
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employed by the Contractor.
(c) Procedures for joint preparation, indicating method and degree of cutting, cleaning,
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drying, scraping, alignment, support, etc. of the pipe ends to be joined.
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(d) Jointing procedures, specifying the equipment and tools to be employed, together with
all relevant parameters such as voltage, temperature, pressure, heating time and
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cooling down time and the means by which jointing operations shall be controlled.
(e) Inspection and testing procedures together with proposals for the independent and on
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site inspection and testing on welds on a regular basis.

(f) QA/QC procedures
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(g) All safety precautions and procedures.

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4.3.6 Electrofusion Jointing

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1 All electrofusion jointing shall be undertaken in accordance with this specification and the
guidance given in DVS 2207-1
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2 Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying
with the requirements of ISO4427, Part 3 shall be used. The electrofusion control unit shall
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incorporate data input through the use of a bar code reader pen and a data retrieval facility to
allow historical fusion data to be read on the unit’s screen and to be exported to an external
computer or memory stick.
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3 The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion
fitting. The power generator shall provide the power requirements of the control box, taking
into account the electrical characteristics of the control box.
4 Positioning tools including suitable alignment clamps shall at all times be used to minimise
misalignment and prevent movement during the fusion and cooling cycle of the joint. A
suitable shelter shall be used in cold, windy, dusty or wet weather conditions.
5 Prior to commencing the welding process the Contractor shall measure and ensure that the
ovality of the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.
6 All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking
the pipe scraping, in order to remove any contamination. Prior to scraping the Contractor
shall measure and mark the area of the pipe or spigot end to be scraped in order to remove
the oxidized surface to a depth between 0.2 and 0.4 mm. The length of the pipe or spigot end
to be scraped shall be equivalent to the insertion depth of the electro-fusion joint plus a
distance of between 10 and 20 mm.
7 Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip
or ribbon over the insertion length of the coupler or fitting, shall be used.
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8 Only after preparation and scraping of the pipe end shall the fitting be removed from its
packaging and immediately inserted over the pipe end.
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9 Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion
socket.
10 Alignment clamps shall not be removed before the appropriate cooling time has elapsed.
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Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior
to commencement of the fusion process.
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4.3.7 Electro-fusion Joint Inspection
ID
1 All completed electro-fusion joints shall be inspected in accordance with the requirements of
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Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the
standard then the electro-fusion fitting shall be cut out and replaced.
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2 After completion of the fusion process, all fusion indicators shall be checked to ensure that
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they are in the position indicated in the Manufacturer's instructions. If any fusion indicators
are not in the required position the electro-fusion fitting shall be cut out and replaced.
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3 The Contractor shall, on a regular basis allow the Engineer to download the historical data
relating to the welds made by the unit through the data retrieval facility.
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4.3.8 Butt Fusion Jointing

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1 All butt fusion jointing shall be undertaken in accordance with this specification, the single low
pressure jointing procedure given in ISO 21307 and the guidance given in DVS 2207-1.
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C
2 Assign a unique joint number to each joint and have a data retrieval facility to allow historical
fusion parameters to be read on the unit’s screen and to be exported to an external computer
or memory stick
ER
3 In the case of large diameter pipes having a high wall thickness in excess of 35 mm the
Contractor may propose to instead follow the single high pressure fusion jointing procedure
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described in ISO 21307. Such a deviation from DVS2207-1 shall only be allowed with the
written approval of the Engineer.
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4 Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.
5 A dummy joint shall be made at the start of each welding session using pipe off cuts of the
same size, material and SDR as the pipe being installed. The normal trimming, bead up and
full heat soak cycles will be adhered to.
6 If the pipe size is changed during the day, if the heater plate is allowed to cool below 180°C
or if maintenance of the butt fusion equipment is carried out then a new dummy weld shall be
performed.
4.3.9 Butt Fusion Joint Inspection
1 All butt fusion joints shall be inspected in accordance with the requirements of Appendix B of
EN 12007 Part 2. Should the joint contain any of the faults described in the standard then the
joint shall be cut out and replaced. The inspection shall include the following points:
(a) The gap between the two single beads shall not be below the fusion surface.
(b) The displacement between the fused pipes must not exceed 10% of the pipe wall
thickness.
(c) The difference between two single bead widths shall not exceed 10% of the double
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bead width.
(d) The weld beads shall be free from all contamination and have a smooth even surface
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with no evidence of distortion, holes or bubbles
(e) At the direction of the Engineer external beads shall be removed with an approved tool
and inspected for contamination and defects. They shall also undergo bend back
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testing. Beads should be solid and rounded with a broad root as hollow beads with thin
root and curled appearance can be indicative of excessive pressure or no heat soak.
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(f) Each removed bead shall be numbered with its corresponding joint number clearly
displayed and removed beads shall be retained for inspection by the Engineer.
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(g) The width of each external bead width shall be measured using bead gauges and the
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width of the bead shall be within the range given by the pipe and / or welding
equipment manufacturer.
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(h) No signs of damage (such as scratches or deep impressions caused by clamps) shall
be visible on either side of the joint.
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(i) Any joints the do not comply with the above requirements shall be cut out and a new
joint made; the failed joint shall be handed over to the Engineer.
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(j) Records of all tests and inspections shall be maintained by the Contractor and made
available for review and approval by the Engineer.
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4.3.10 Testing of Fusion Joints

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1 A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under
laboratory conditions in accordance with ISO 13953 by an approved testing organisation. The
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joints to be tested shall be selected by the Engineer immediately upon completion of the
welding process, whereupon they shall be cut out and delivered for testing.
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2 A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested under
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laboratory conditions in accordance with ISO 13954 by an approved testing organisation. The
fittings to be tested shall be selected by the Engineer immediately upon completion of the
welding process, whereupon they shall be cut out and delivered for testing. They shall
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comprise at least 1 of each type of electro-fusion fitting even if this requires more than 1 % of
all electro-fusion fittings to be tested. Note that the minimum test requirement is for one fitting
of each type i.e. bend, coupling, tapping saddle, tee etc. not one of each size and type.
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3 All costs associated with the testing, together with any consequent rectification of faults and
retesting shall be borne by the contractor.
4.3.11 Anchorage
1 Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and tie
rods used where there is a possibility of pulling the joint under pressure. Concrete thrust
blocks shall be used in lieu of the above where socket and spigot pipe is used below ground.
The Contractor shall submit, for the Engineer’s approval, working drawings and information
demonstrating the adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
4.4 PIPE LAYING
4.4.1 General
1 Except as otherwise specified in this Clause, pipe bedding shall conform with the
requirements specified in Part 2 of this Section.
2 The Contractor shall, after excavating the trench and preparing the proper bedding, furnish all
necessary facilities for properly lowering and placing sections of the pipe in the trench without
damage and shall properly install the pipe.
ST
3 Each pipe shall be carefully lowered onto its prepared bed by means of appropriate slings
and tackle. A recess shall be left in the prepared bed to permit the sling to be withdrawn. If
EA
the prepared bed is damaged, the pipe shall be raised and the bed made good before pipe
laying is continued.
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4 No pipe shall be rolled into place for lowering into the trench except over suitable timber
planking free from roughness likely to damage any coatings.
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5 The section of pipe shall be fitted together correctly and shall be laid true to line and grade in
accordance with the bench marks established by the Contractor. The bench marks shall be
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approved by the Engineer.
6
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The full length of the barrel of the pipe shall have a uniform bearing upon the bedding
material and if the pipe has a projecting socket, suitable excavation shall be made to receive
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the socket which shall not bear on the subgrade.
IN
7 Pipes shall be laid with the class identification marks or the jointing marks shown by the
manufacturer in the uppermost position. Pipe sections shall be so laid and fitted together
LT
that the pipeline will have a smooth and uniform interior. The pipeline shall be clean and
unobstructed at the time of its installation and shall be true to the required line and levels.
SU
8 Spigot and socket pipes shall generally be laid upgrade without break from structure to
structure and with the socket end upgrade. Backlaying may be permitted as deemed
necessary and approved by the Engineer.
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9 Whenever work ceases on any pipeline the unfinished end of the pipeline shall be securely
closed with tight fitting plug or cover.
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10 Before any pipe is lowered into place, the bedding shall be prepared and well compacted so
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that each length of pipe shall have a firm and uniform bearing over the entire length of the
barrel.
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11 Pipes shall be laid in straight lines, both in the horizontal and vertical planes, between
manholes or, where directed in the case of pressure pipelines and larger diameter sewers to
regular curves. The placement of pipes shall comply with the following requirements:
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(a) each pipe shall be plumbed to its correct line and directly and accurately sighted by
means of a laser positioning system or boning rods and sight rails fixed to secure
posts which shall be set up and maintained at each end of the sewer to be laid and
not more than 20 m apart. Sight rails shall be clearly painted in contrasting colours
and be not less than 150 mm deep, straight and level
(b) boning rods shall be of robust construction clearly painted and accurately made to the
various lengths required, the lower end being provided with a flat edged shoe of
sufficient projection to rest on the invert of the pipes as laid. The boning rod shall be
complete with a vertical spirit level
(c) boning rods and sight rails shall not be removed until the pipeline has been checked
and approved by the Engineer
(d) alternative methods of locating and levelling pipelines may be allowed subject to the
approval of the Engineer
(e) any pipe which is not in true alignment, both vertically and horizontally, or shows any
undue settlement after laying, shall be taken up and relaid correctly by the Contractor
(f) all adjustments in line and grade shall be made by scraping away or filling and
tamping in under the barrel of the pipe and not by wedging or blocking
(g) the trench shall be kept completely dry
(h) in no case shall pipes be jointed before being lowered into position
ST
(i) the gasket should be positioned and lubricated.
12 Pipelines shall be tested in accordance with Subpart 4.5.
EA
4.4.2 Laying of Rigid and Semi-Rigid Pipes
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1 Each pipe immediately before being laid shall be carefully brushed out and inspected for
defects. In trench pipes with flexible joints except where concrete bed, bed and surround or
protection is required shall be laid on a well compacted bed of granular material extending for
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the full width of the trench and with sufficient material at the sides to permit the pipes to be
worked into the granular material and firmly supported to true line and level. Sufficient space
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should be left to enable the joints to be made tested and inspected but the Contractor shall
ensure that at least three quarters of the pipe length is fully supported. After the pipeline has
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been tested and approved by the Engineer the trench shall be carefully filled to 300 mm
above the crown of the pipe with granular material in accordance with the bedding
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requirements specified in Part 2 of this Section and as shown on the Drawings.
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2 Vitrified clay pipes shall be installed in trenches which shall not exceed the maximum trench
width at 300mm above crown of pipe as shown in Table 2.1 of Part 3 of this Section.
LT
3 Should the Contractor exceed the trench widths given in Table 2.1 he shall provide
calculations to show the loading on the pipe and bedding requirements and where required
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he shall provide plain or reinforced concrete cradle or surround, to the approval of the
Engineer, at no additional cost. The same type of pipe bedding/surround shall be used for
the full sewer length between adjacent manholes.
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4 Unless otherwise specified, pipe bedding shall be as shown on the Contract Drawings.
Notwithstanding the above, for Vitrified Clay pipe the special pipe bedding requirements as
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Table 4.2 are to be provided in all cases whether or not shown on the drawings or indicated
in the bills of quantity.
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Table 4.2 - Special Bedding Requirements for VC Pipes

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Nominal bore Depth to Invert (D)

Bedding Type*
mm m
H
700-800 D>9.0 4.1.1.1.1 Plain concrete cradle
>900 4.0<D<5.0 4.1.1.1.2 Plain concrete cradle

Reinforced concrete cradle with minimum
>900 5.0<D<9.0
0.4% transverse steel
Reinforced concrete surround with minimum
>900 D>9.0
of 1% transverse steel.
(* as shown on drawings)
4.4.3 Laying of Flexible MDPE and HDPE Pipes
1 This clause does not apply to GRP pipes for which laying requirements are given in Clause
4.3.4 of this Section.
2 All operations involving the laying, bedding, jointing, backfilling etc. of pipes of plastic
materials shall be strictly in accordance with the manufacturer’s recommendations subject to
the approval of the Engineer.
3 The pipeline shall be laid on a well compacted sand or granular material that shall extend
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across the full width of the trench bottom. The pipe bed shall have a minimum thickness of
100 mm and be compacted to a minimum modified Proctor (AASHTO) density of 90% prior
to the laying of the pipeline.
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4 After laying of the pipeline the Contractor shall place pipe surround material on both sides of
the pipe, ensuring that no cavities are left between the underside of the pipe and the trench
bottom or pipe bed. The pipe surround material shall be placed in layers of no more than 150
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mm thick and compacted with hand tools across the width of the trench to achieve a
minimum Modified Proctor (AASHTO) density of 90%. The pipe surround shall extend to a
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minimum of 200 mm above the crown of the pipe.
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5 Where pipes are laid in good quality ground conditions such as those native soils comprising
granular, sandy or rocky materials, the pipe bed and surround shall comprise clean dry sand
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free from silty and foreign materials and particles of larger than 10 mm diameter.
6 The maximum particle size of the granular material shall also not exceed 10% of the pipe
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outside diameter.
IN
7 Should the excavated native soil fail to meet the above requirements it shall be graded on
site in order to do so or be replaced with an imported sand or granular material complying
LT
with the requirements of the UK WIS 4-08-02 or this specification.

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8 Where pipes are laid in poor quality ground conditions such as those native soils comprising
soft or silty materials, the pipe bed and surround shall comprise an imported granular
material complying with one of the grades given in the UK WIS 4-08-02 or this specification.
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9 Single sized aggregate shall not be used for the pipe bed and surround in conditions where
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the native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile
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filter fabric to prevent migration of fine material from the surrounding soil in to the bed and
surround
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10 When the grade at which the pipeline laid exceeds 10 trench breakers or clay dams shall be
installed to prevent the migration of bed and surround material due to the flow of water along
the trench.
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4.4.4 Laying of GRP Pipes

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1 During the mobilisation period the Contractor shall submit for the Engineer’s approval the
pipe manufacturer’s complete and detailed specification for the handling and installation of
pipe and fittings in open trench and such other methods of construction of pipeline specified
or proposed by the Contractor. This specification shall be submitted during the mobilisation
period irrespective of whether the data was submitted with the Tender.
2 The Contractor shall transport, store, handle and lay pipes in accordance with the approved
manufacturer’s handling and installation specification as approved by the Engineer.
3 The manufacturer’s handling and installation specification shall include details of the
manufacturer’s technical expert to be assigned to the Contract. The technical expert shall
have extensive experience of handling and installation of GRP and shall be fully familiar with
the manufacturer’s handling and installation specification.
4 The manufacturer’s technical expert shall provide comprehensive technical assistance to the
Contractor throughout the Contract and shall regularly monitor the Contractor’s handling and
installation operations.
5 Any instructions or advice given by the manufacturer’s technical expert to the Contract shall
ST
be copied to the Engineer. In the event that the Contractor deviates from the approved
handling and installation specification, the manufacturer’s technical expert shall immediately
inform the Contractor and the Engineer.
EA
6 All costs associated with the provision of a technical expert by the manufacturer shall be
borne by the Contractor.
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7 GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding
material. The space below the barrel of the pipes shall be filled with special bedding material
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to the full width of the trench in layers not exceeding 150 mm in thickness. After pipe laying,
further special bedding shall be placed and thoroughly compacted to fill the entire space
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between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the
top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe
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shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater
thickness of special bedding below, around and over the pipes than those specified they shall
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be deemed to have been allowed for in the rates for bedding.
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8 Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first
100 mm of pipe at entry to the structure shall be surrounded by an approved flexible material.
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Flexible joints shall be incorporated adjacent to structures, in accordance with Clause 4.2.4.
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9 Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed
with two layers of resin, the second layer being paraffin wax filled to ensure full cure.
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10 Where GRP pipes are required to be surrounded with concrete, all necessary precautions
shall be taken to ensure that maximum allowable deflections are not exceeded. Adequate
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precautions are to be taken to ensure that the pipe does not float during placing of the
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concrete surround.
11 At all times, backfilling shall be carefully carried out to ensure no voids or pockets of
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unconsolidated material are present. The Contractor shall monitor the vertical deflection of
the pipes throughout the backfilling operation. No pipe shall exhibit more than 1.5% deflection
after placing and compaction of the granular bed and surround. In addition, after completion
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of the trench backfilling, the average deflection of a length of pipe shall not exceed 1.5%, and
every pipe shall be demonstrated to exhibit no more than the manufacture’s calculated
allowable ‘Initial Deflection’, or 3.5% deflection, whichever is smaller. If any of these values
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are exceeded, the affected pipes shall be exhumed and re-laid.
12 The deflection shall also be checked on each length between manholes or chambers before
commissioning to determine whether longer term deflections are within permissible limits.
The average deflection of a length of pipe shall not exceed 3%, and every pipe shall be
shown to exhibit a deflection no greater than 5%, or the calculated allowable deflection
consistent with the achievement of a long term deflection not exceeding 5%, whichever is
smaller, at any point. Pipes exhibiting greater deflections shall be exhumed and re-laid.
13 Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated allowable long term
deflection, shall be exhumed, indelibly marked ‘REJECTED’, removed from the site and not
reused.
4.4.5 Corrosion Protection of Ferrous Pipelines
1 Where tape wrapping is wrapped at site it shall be applied by machine under factory
controlled conditions in accordance with Clause 3.7.6 of this Part.
2 Pipe joints shall be protected by continuing the tape wrapping, or by heat shrink polyethylene
tubes coated internally with thermoplastic adhesive. The profile of the pipe joint shall be
smoothed using bituminous mastic or preformed plastic foam sections taped in position.
Heat shrink sleeves shall be on pipes with extruded polythene coatings, and in all cases shall
be applied in accordance with the sleeve manufacturer’s and pipe coating manufacturer’s
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instructions.
3 Joints within in-situ concrete chambers do not require heat shrinkable sleeve protection.
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4 Damaged areas of protective coating or wrapping shall be repaired in a manner to be
approved by the Engineer’s Representative.
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5 Ferrous pipelines shall be supplied with one of the following corrosion protection systems:
(a) Cold applied self-adhesive laminate tape wrapping
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(b) Extruded polyethylene coating
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(c) Loose polyethylene coating M
6 Extruded polyethylene coating shall be as Clause 3.7.7. Heat shrink sleeves shall be used
over joints in polyethylene coated buried pipes.
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7 Spigot ends of pipes coated in either of the approved manners shall not be coated over the
IN
depth of engagement within the socket or flexible coupling, but shall be coated with epoxy,
polyethylene or polyurethane for pipes internally lined with these materials.
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8 Where ductile iron buried pipe is designated to be encased in loose polythene sleeving,
installation shall be in accordance with BS 6076.
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9 The pipe shall be supported by a central sling and a length of sleeving pulled over the spigot
end and bunched up to the sling.
N
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10 The pipe shall then be rested on blocks placed at its extremities and the sleeving pulled up to
the socket and folded and taped or tied in position. The sling shall then be replaced to
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enable jointing to be carried out. A wide sling shall be used to distribute the weight and thus
obviate intense pressure on the sleeving. Care shall be taken to avoid damage when
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removing the sling from the trench.
11 The sleeve shall not be drawn up over the pipe joints until the completion of the hydrostatic
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testing. Immediately after making the pipe joint, the pipe trench shall be backfilled as
described hereinbefore in readiness for the hydraulic testing and to prevent damage to the
sleeving.
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12 After completion of the hydraulic testing, the sleeving shall be drawn up over and fixed
around the pipe joints. A pad of sleeving shall first be placed around the joint to prevent
damage to the joint sleeve by the edges of the socket or by bolts. A length of sleeving shall
then be drawn over joint overlapping itself either side of the joint for a minimum of 300 mm
and this shall be tied or taped tightly in position.
13 Any pipe sleeving perforated during fitting shall be repaired by overlaying with a short sleeve
folded and secured with tape. Torn or damaged sleeving which is considered by the Engineer
as not repairable by this method shall be replaced by the Contractor.
14 Immediately after fitting the pipe sleeving the pipe trench shall be partly backfilled to prevent
damage to the sleeving.
4.4.6 Concrete Protection to Pipe
1 Where concrete protection to pipelines is specified or ordered by the Engineer’s

Representative a 75 mm thick Grade 20 concrete layer shall be laid over the full width of the
trench and never less than 150mm wider on each side than the barrel of the pipe and with its
top surface positioned as shown on the drawings.
ST
2 This concrete shall be allowed to set and be thoroughly washed down before pipe laying is
started.
EA
3 The length of pipeline laid in any one operation before concreting the pipeline shall be that
which in the opinion of the Engineer’s Representative permits accurate laying of the pipeline
and proper compaction of the fill.
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4 Pipes up to 1200mm diameter shall be firmly supported on precast concrete blocks and
separated from them by 25mm thick saturated softwood packing.
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5 Pipes greater than 1200mm diameter shall be firmly supported on precast concrete blocks
ID
and separated from them by saturated softwood packing 38mm thick.
6
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Alternatively for pipes up to 300mm diameter a layer of concrete Grade 20 of minimum water
content can be laid on the 75mm concrete layer and the pipes worked into this concrete to
true line and level before it sets. Sufficient space shall be left to enable joints to be made,
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tested and inspected but the Contractor shall ensure that the barrel of the pipe is fully
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supported for at least two thirds of the pipe length.
After the pipeline has been tested, and approved by the Engineer’s Representative, the
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concrete shall be thoroughly washed down and additional concrete Grade 20 shall be
carefully placed and compacted thereon to avoid disturbing the pipes or joints until the
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appropriate profile for the type of protection required has been reached.
Minimum thickness of
Nominal bore of pipe
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surround
mm
mm
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Up to and including 500 150

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500 – 900 250

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1000 – 1100 300

1200 - 1400 350
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>1400 400
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8 Concrete protection to the pipelines shall be concrete cradle or concrete surround as detailed
on the Drawings and shall be of concrete Grade 20. The thickness of the concrete surround
below, to the sides and above pipes shall be as follows:
9 When support of excavation is provided building paper shall be placed against that support
before concreting to facilitate withdrawal of support.
10 In the case of spigot and socket pipes with flexible joints the concrete protection at each joint
shall be interrupted in a vertical plane at the edge of the socket by a strip of fibreboard or
other material approved by the Engineer’s Representative and of the following thickness:
Up to 300mm nominal bore - 13mm
Over 300 and up to 600mm nominal bore - 25mm

Over 600 and up to 1200mm nominal bore - 38mm
Over1200 and up to 2000mm nominal bore - 50mm
11 The protection and filling of headings shall be of mass concrete Grade 20 and may be carried
out in one operation.
4.4.7 Deflection Criteria for Flexible Pipelines
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1 All flexible pipelines will be subjected to deflection measurements at Site. Sections of pipe
failing to meet the specified deflection criteria shall be removed from the trench and relaid,
provided the pipe is not damaged. This procedure shall be repeated until the pipeline is
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found to be satisfactory. Removal from the trench and relaying shall be an obligation of the
Contractor. If the permanent set or deflection, after removal, exceeds the limits set out
below, the pipes shall be deemed to be damaged and will therefore be condemned. Pipes so
condemned shall be indelibly marked, removed from the Site, and replaced by the
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Contractor.
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2 At all times, backfilling shall be carefully carried out to ensure that no voids or pockets of
unconsolidated material are present. The Contractor shall monitor the vertical deflection of
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the pipes throughout the backfilling operation. No pipe shall exhibit more than 3.0 %
deflection after placing and compaction of the granular bed and surround. In addition, after
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completion of trench backfilling, the average deflection of a length of pipes shall not exceed
3.0 %, and every pipe shall be demonstrated to exhibit no more than the manufacturer’s
calculated allowable initial deflection, or 5.0 % deflection, whichever is the smaller. If any of
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these values is exceeded, the affected pipes shall be dismantled and relaid.
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3 MDPE and HDPE (PE) pipes may be bent or curved on site down to a minimum radius as
recommended by the manufacturer. In the event of the manufacturer providing no
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recommendation, the minimum bend radius shall not be less than 25 times the pipe OD,
Where there are space restrictions the bend radius may be reduced down to 20 times the
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pipe OD, but only with the written permission of the Engineer.
4 No electro-fusion or mechanical joints should be incorporated in the sections of PE pipework

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which are to be bent. Instead a formed bend or elbow should be welded in the pipeline in
order to prevent excessive stress.
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5 The deflection shall also be checked on each length between manholes before
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commissioning to determine whether longer-term deflections are within the specified limits.
The average deflection of a length of pipes shall not exceed 3 %, and every pipe shall be
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shown to exhibit a deflection no greater than 5 %, whichever is the smaller, at any point.
Pipes exhibiting greater deflections shall be exhumed and relaid.
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6 Pipes exhibiting a deflection greater than 8 % or 1.6 times the calculated allowable long term
deflection, shall be exhumed, indelibly marked “REJECTED”, removed from site and not
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reused.
4.4.8 Backfilling
1 The requirements of Part 2 of this Section shall apply, except as otherwise specified in this
Clause.
2 After the pipeline has been tested and approved by the Engineer, the trench shall be carefully
backfilled to 300 mm above the crown of the pipe for rigid pipes with granular material.
Backfilling of the pipe trench should be carried out as designated, or shown on the Contract
Drawings.
3 Where concrete bedding or surround is required, the backfill shall not be placed before the
compressive strength of the site concrete has reached 15 MPa.
4 Where concreting to pipeline is specified, a blinding layer of Grade 20 SRC concrete shall be
placed over the full width of the trench or heading.
5 Pipes to be bedded on or cradled with concrete shall be supported on precast concrete

setting blocks, the top face of each block being covered with a separation layer.
6 Concreting to the pipeline shall be either bed or bed and surround as shown on the Drawings
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and shall be of Grade 20 SRC concrete along such lengths as are shown on the Drawings or
ordered by the Engineer.
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7 The pipe shall be prevented from moving during concreting.
8 Where concrete bed and surround is used with GRP and PVC-U pipes the maximum spacing
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between pipe joints shall be 3 m. For other pipe materials the maximum spacing shall be as
directed by the Engineer.
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9 When support of excavations is provided, building paper shall be placed against that support
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before concreting to facilitate withdrawal of the support. Building paper shall comply with BS
1521 Class ‘A2’. M
10 In the case of pipes with flexible joints, the concrete at each joint shall be interrupted in a
vertical plane at the edge of the socket by a strip of fibreboard or other material approved by
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the Engineer and of the following thicknesses:
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Up to 300 mm nominal bore - 13 mm

Over 300 mm and up to 600 mm nominal bore - 25 mm
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11 The protection and filling of headings shall be of Grade 20 SRC concrete.

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12 Where concrete slab protection to GRP and PVC-U pipelines is required such protection
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shall extend a minimum of 200 mm either side of the pipe trench. The slab shall be of
reinforced concrete as shown on the Drawings.
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4.4.9 Deflection at Joints

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1 Where the Engineer orders or allows a change of direction to deflect pressure pipelines from
a straight line, either in the vertical or horizontal planes to avoid obstruction or where long
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radius curves are permitted, the amount of deflection allowed shall not exceed that required
for satisfactory connection of the joint and shall be approved by the Engineer. Where a
change of direction cannot be made by deflection at the joints of ordinary straight pipes,
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bends shall be used. The locations of such bends and other specials are shown on the
Contract Drawings and their exact positions will be determined by the Engineer on the Site.
4.4.10 Wadi Crossings
1 Work at any crossing of a wadi or other waterway shall be carried out as expeditiously as
possible to the satisfaction of the Engineer and any responsible Government agency or other
authority, with minimum interference to the free flow of water. Details of any temporary works
which may affect the flow of the wadi shall be submitted to the Engineer at least 14 days
before starting work.
2 Where pipelines passes underneath a wadi, ditch, open surface water channel, or other
waterway, the pipelines shall be encased in concrete. The minimum thickness of encasement
shall be 150 mm. Unless otherwise designated, the depth of cover shall not be less than 600
mm from the bed of the water coarse to the top of the concrete.
3 The Contractor shall fill the trench in both banks with rock fill or concrete up to the designated
levels. The extent of this work may be varied to suit each individual crossing. Unless
otherwise ordered, the concrete encasement of the pipe shall extend at least to a section
vertically below the tops of the banks. Protection against erosion to the banks shall be
provided by means of stone pitching or riprap.
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4.4.11 Pipe Supports
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1 Pipe hangers and saddle supports shall be of standard manufacture as shown on the
Drawings and in compliance with the following general requirements:
(a) piping shall be supported independently from appurtenances to which it is affixed.
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(b) all weight of piping and contained fluids shall be transferred to a structures or
foundation system through stools, brackets, pipe saddle supports, or overhead hanger
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systems.
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(c) a support shall be provided for each pipe at or near the point where it is connected to
machinery or valves. A support shall be provided for each valve and special fitting.
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(d) flexible joints shall be required at either ends of the support system.
(e) where necessary, expansion joints shall also be provided.
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(f) pipe hangers and supports shall generally be fabricated in Mild Steel. These shall be
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galvanised and painted with coal tar epoxy.
2 For pipelines to be fixed in culverts, the Contractor shall prepare proposals for thrust and
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anchor support and submit them to the Engineer for approval. Such approval shall not relieve
the Contractor from his responsibility for the adequacy of his proposal. Additional
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requirements for both location and details of supports may be shown on the Drawings or
directed by the Engineer as the work proceeds to suit the actual conditions encountered.
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4.4.12 Building-in Pipes to Structures

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1 Pipes constructed into a concrete wall or structure shall be protected with a concrete
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surround integral with the external face of the structure as shown on the Drawings.
2 All internal and external protection membranes to the concrete shall be sealed around the
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pipe openings as recommended by the membrane manufacturer. When the pipe is later
fixed, the remaining hole shall be re-formed and filled with non-shrink grout.
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3 Any over-excavation adjacent to a structure or beneath the formation level of a pipeline,

either to be constructed under the Contract or in a future contract, shall be backfilled with
Grade 20 SRC concrete.
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4 Pipes and pipe specials through concrete walls and floors shall as far as possible be
positioned and built in during construction. They shall be located exactly in the positions
shown in the Contract Drawings and shall be true to line and level. The Contractor shall take
particular care to ensure that fully compacted concrete is in contact with the pipe at all points.
5 Where it is impracticable to cast pipes and specials in the concrete, boxouts shall be
provided in the formwork. The box shall have six or eight sides, depending on the pipe
diameter, and shall be no larger in size than will give adequate clearance for the subsequent
positioning and grouting in of the pipe. The sides of the boxout shall be provided with a
tapered central annular recess to provide a positive key. The boxout shall be provided with a
grout hole and, at the top of the central annular recess a vent hole. The boxhole shall be
stripped with the main formwork and the concrete surface thoroughly cleaned and
roughened.
6 Unless otherwise shown on the Contract Drawings, where pipes pass through a concrete wall
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or structure they shall be protected with a surround of Grade 20 SRC concrete integral with
the external face of the structure. For pipes of less than 500 mm diameter, the surround shall
extend from the wall or structure by 300 mm and the width and depth of the surround beyond
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the outside face of the pipe at its horizontal and vertical diameters shall be a minimum of
300 mm or as otherwise indicated on the Drawings. For pipes of 500 mm diameter or greater
the surround shall extend from the wall or structure by 500 mm and the width and depth of
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the surround beyond the outside face of the pipe at its horizontal and vertical diameters shall
be 500 mm or as otherwise indicated on the Drawings.
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7 On socket and spigot pipelines except those of GRP or other plastic materials the socket end
of the pipe passing through the wall shall be flush with the outside face of the concrete
surround. On socket of spigot pipelines of GRP or other plastic materials the socket end of
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the pipe passing through the wall shall protrude 300 mm from the concrete surround. A
protective synthetic rubber strip 6 mm thick and 150 mm wide shall be provided around the
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pipe at the limit of the concrete surround as shown on the Contract Drawings.
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8 On all other flexibly jointed pipes the plain end of the pipe shall protrude from the concrete
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surround by a maximum of 300 mm or that distance required to properly make the joint.
9 The first pipe that is clear of concrete surround beyond the external face of a concrete wall or
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structure shall be a short length of either spigot and socket or double spigot to suit the flow
direction and pipe material. The effective length of this pipe shall be 1.5 times the nominal
bore or 600 mm whichever is the greater.
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10 For mechanically jointed pipes the plain end shall protrude from the surround by a maximum
of 300 mm or that distance required to make a proper joint.
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11 Where the structure is tanked, Grade 20 OPC concrete shall be used and the tanking shall
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extend to the concrete surround.
4.4.13 Cleanliness of Pipelines

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1 Pipelines and manholes shall at all times be kept free of all silt, mortar, debris and other
obstructions. When work is not in progress the open ends of the pipeline shall be securely
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plugged with an approved watertight plug or stopper firmly fixed to resist unauthorised
removal. Claw type plugs or any type liable to damage the pipe shall not be used. All such
stoppers, plugs or caps shall be provided with a vent incorporating a valve for the purpose of
testing whether the pipeline is under pressure or vacuum and to enable pressures to be
equalised before its removal.
2 The Contractor shall clear the inside of each fitting and pipe length immediately before
jointing and shall swab all fittings and pipe lengths to remove all dirt, sand or other matter that
may clog the pipeline or contaminate the fluid to be transported in the pipeline. After jointing,
the interior of the pipes shall be freed from any dirt, stones or other matter that may have
entered them. For this purpose, a rubber disc, brush, or other suitable implement that will not
harm the internal lining of the pipe shall be pulled through the pipe after jointing.
3 Pressure pipelines and treated sewage effluent pipelines shall be flushed and a swab passed
through. Large diameter pipelines shall be visually inspected internally to the approval of
Engineer.
4.4.14 Marker Tape
1 All trenches for pressure pipelines, shall be marked with a high quality acid and alkali-
resistant red non bio-degradable plastic tape with a minimum width of 150 mm placed during
backfilling 300 mm below finished surface or as directed by the Engineer. These tapes shall
2 2
have a minimum strength of 125 kg/cm in the longitudinal direction and 105 kg/cm
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transversely with an elongation factor in the longitudinal direction of 350 percent. The text on
the tape shall be permanent black ink bonded to resist prolonged chemical attack by
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corrosive acids and alkaline with message repeated at a maximum interval of two metres.
Tapes over non-ferrous pipes shall be detectable by electro-magnetic means using low
output generator equipment.
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2 The tape wording and colour shall be as follows:
WORDING COLOUR
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DANGER : FOUL SEWAGE RED
ID
CAUTION TREATED SEWAGE EFFLUENT GREEN
SURFACE WATER
M GREY
WATER MAIN BLUE
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DANGER : FUEL PIPELINE BROWN

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3 The tape shall be laid continuous over pipelines and at joints there shall be a minimum of one
metre overlapping. Tape shall be terminated inside valve boxes to allow clipping of detector
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equipment to the tape.

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4.4.15 Pressure Pipeline Marker Posts
1 Pipeline marker posts shall be provided at all points where the pipeline crosses boundaries
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or changes direction and elsewhere at maximum intervals of 100m. Each marker post shall
be set over the centreline of the pipelines with concrete Grade 20 SRC concrete base
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surround in accordance with the Contract Drawings. Marker posts shall incorporate a
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description of the pipeline and its service in Arabic and English to the approval of the
Engineer. Offset marker posts may also be used in areas where the post could not be
installed over the centreline of the pipelines.
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2 Coloured marker plates shall be made from multi-layered plastic, green for TSE and orange
for foul sewage.
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4.4.16 Valve Chamber Marker Posts

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1 Valve chamber marker posts shall be installed at all chambers, indicating the type of
chamber, its reference number and distance from the marker post in Arabic and English to
the approval of the Engineer.
2 Where the pipeline is in a footpath or verge, the marker post shall be installed against the
wall or property boundary and facing the chamber cover, with Grade 20 SRC concrete base
surround.
4.4.17 Abandonment of Pipelines
1 Pipelines and service connections to be abandoned shall first be emptied completely.

2 Pipelines and service connections to be abandoned shall be filled completely with a cement
slurry or concrete using a grout pan or an alternative method approved by the Engineer such
that the discharge slurry or concrete can be forced into the pipeline under pressure.
3 The Contractor shall ensure that all existing connections to the sewer to be abandoned have
been plugged or disconnected before beginning filling.
4 The Contractor shall inform the Engineer of his intention to begin this operation and shall
obtain the Engineer’s approval in writing for the abandonment of each particular length before
beginning filling.
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5 Upon completion of the above procedure, the Contractor shall undertake abandonment of
manholes inspection chambers and other structures. Where a pipeline or service connection
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to be abandoned connects into a manhole or chamber to be retained, the connection shall be
plugged at the chamber wall and the associated channel in the benching of the manhole or
chamber shall be cleaned and filled with concrete Grade 20 SRC. The benching shall then
be covered with the appropriate protective lining to match the existing manhole lining.
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6 Unless otherwise designated, existing pressure pipelines to be abandoned shall be emptied
and sealed at each end of the pipeline with a removable expanding stopper to the Engineer’s
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approval. The stopper shall include a valve for the purpose of venting and for the equalising
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internal and external pressures removal. Any chambers located along the pipeline to be
abandoned shall be demolished and the pipeline ends sealed as specified.
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4.4.18 Abandonment of Structures
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1 Where manholes, septic tanks, cesspits, soakpits and other structures are to be abandoned,
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they shall be emptied of their contents to the approval of the Engineer. The contents
including sludge from these structures, whether undiluted or mixed with sand, shall be
disposed of off the Site by the Contractor to a location approved by the Engineer. The
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Contractor shall submit in writing his proposals for emptying the contents and disposal. No
work shall begin on demolition until the structure has been completely emptied.
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2 After desludging, the roof slabs and tops of walls of the structure shall be demolished to an
elevation not less than 500 mm below existing ground level. The fragments of demolished
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structures may be used to partially fill the void. Voids shall be filled up with sand, watered and
well compacted up to the elevation of the underside of the cover slab. The frames and
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covers of manholes and chambers shall be removed by the Contractor and delivered to the
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designated Employers’ stores and placed into storage.

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3 If an existing service is found within a structure to be abandoned, the Contractor shall inform
the Engineer and carry out the Engineer’s instructions for ensuring that the service pipeline is
retained or restored. If a sleeve is to be provided, the sleeve shall extend for 100 mm on
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either side of the structure. When backfilling or working around an existing service or sleeve,
the Contractor shall take all precautions to ensure that no damage occurs and that there is
no interruption of service.
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4.4.19 Corrosion Protection of Flexible Couplings and Ferrous Fittings
1 Buried flexible couplings, including flange adaptors shall be protected as follows:
(a) Mastic paste filling (Denso paste or similar)

(b) Mastic tape wrapping (Denso tape or similar)
(c) and finished with cold applied self-adhesive laminate tape wrapping (or heat shrink
sleeving) in accordance with Clause 8.4.3.5
2 Couplings, including all associated nuts and bolts, within chambers or pumping stations shall
be polyamide powder coated (“Rilsan” or similar).
4.5 PIPELINE STRUCTURES AND APPURTENANCES
4.5.1 Manholes for Foul Sewerage
1 The Contractor shall prepare a standard record sheet for every manhole and structure and
shall submit to the Engineer for information only.
2 Manholes shall be constructed as shown on the Contract Drawings and at the locations
indicated thereon or at other locations directed by the Engineer.
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3 The blinding concrete shall be mass concrete Grade 25 SRC concrete and the manhole base
slab, benching and insitu concrete walls shall be Grade C40 SRC concrete.
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4 Precast concrete manhole rings shall be manufactured using Grade C50 SRC concrete. The
joint surfaces and outer face of the precast concrete rings shall have factory applied epoxy
coating in accordance with Part 8 Clause 8.3.15. The inner face of the precast manhole ring
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shall be a prefabricated GRP liner at least 6mm thick bonded by lugs to the concrete. The
completed joints between precast concrete rings shall have an insitu applied sealing strip at
least 6mm thick overlapping the GRP liner by a minimum of 150mm each side. The sealing
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strip shall be capable of withstanding the full hydrostatic head of external ground water to
ground level and the maximum internal hydrostatic head, whichever is the greater.
5
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The underside of the base and the external faces of insitu concrete bases and walls shall be
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protected with a membrane tanking system. The necessary period for setting, as
recommended by the manufacturer, shall be allowed before beginning other works to
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complete the construction of the manhole.
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6 The cover slab shall be surmounted by ductile-iron manhole cover and frame of the quality
specified. The covers in road and paved areas shall be accurately set on precast concrete
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segments to the level and slopes of the roads or pavements.
7 In the case of shallow manholes, the cover and frame may be cast directly monolithic with the
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reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract

Drawings.
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8 The interior face of manholes and access shafts shall be prefabricated GRP liners at least
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6 mm thick permanent lining.

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9 Prefabricated GRP benchings and channels shall be preformed, inverted and filled with
Grade C40 SRC concrete. Alternatively, the GRP lining may be applied to the in-situ
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concrete benching after constructing the benching.
10 GRP lining to walls shall incorporate lugs moulded onto the outside face at 500 mm centres
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to allow bonding to the concrete surround. The lining shall have adequate strength to
withstand handling, and shall not buckle or distort during pouring of the concrete surround.
Internal bracing may be used during pouring of the concrete surround. Internal bracing may
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be used during pouring to maintain circularity and verticality.
11 Cover slabs shall be precast using Grade C50 SRC concrete and shall incorporate a
preformed flat sheet of GRP on the soffit, bonded to a GRP tube to form the access opening.
Both linings shall incorporate lugs moulded onto the surface to allow bonding to the concrete.
The overall size of the lining to the soffit of the slab shall be 150mm greater than the internal
diameter of the manhole onto which the slab is to be placed.
12 In all cases, the outer surface of the GRP, exposed to the sewage atmosphere, shall consist
of a chemically resistant layer comprising vinyl ester resin suitably reinforced with a ‘C’ glass
or synthetic tissue veil. This layer shall be no less than 2mm thick, and shall have a resin
content by weight of approximately 90% at the exposed surface, reducing to 65% - 75% at
the inner surface. The remainder of the liner shall consist of vinyl ester or isophthalic resins
and “E” or “ECR” glass chopped strand mat. Fillers, such as silica sand and calcium
carbonate shall not be used. Loss of Ignition Test to BS 2782 (method 1002) shall be
conducted on random samples of GRP manhole liner to detect percentage of glass and the
presence of any silica sand filler.
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13 Joints in the lining tubes of insitu concrete manholes shall not normally be permitted.
14 Joints between preformed GRP benchings and lining tubes shall be made using an external
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sleeve 200 mm long bonded onto both units, and then bandaged using suitable resin and
chopped strand mat prior to casting the insitu concrete walls. Such bandaging shall extend
75 mm either side of the edge of the sleeve. On the inside face of the manhole, the joint
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between the benching and liner tube shall be filled with vinyl ester paste to produce a smooth
finish.
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15 If GRP linings to benchings are to be formed in situ the surface of the wall lining tube shall be
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lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius shall
then be formed of vinyl ester paste at the junction of benching and wall. The GRP lining to
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the channels and benchings shall then be built up by applying isophthalic or vinyl ester resin
to the whole of the benching, fillet and abraded wall lining. A layer of “E” or “ECR” mat shall
than be rolled into the resin using a suitable steel roller to exclude all air and provide
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complete immersion of the glass fibre in the resin. After a period to allow pre-gel to a tacky
state a second coat of resin shall be applied followed by a further layer of glass fibre mat.
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This process shall be repeated until the total thickness of lining is approximately 4 mm. Vinyl
ester resin and “C” glass or synthetic tissue veil shall then be used to complete the lining.
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16 Top surfaces of benchings shall incorporate silica sand to form a non-slip surface.
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17 The precast cover slab shall be seated on the walls using sand/cement mortar. The joint
shall be raked out 15 mm deep on the inside face and pointed with an approved pitch
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extended polyurethane sealant.

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18 Ladders in structures where shown on the drawings shall be fabricated in stainless steel
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Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
stainless steel.
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19 Intermediate the Contractor shall provide the Engineer with a 10 year unconditional
guarantee against failure of all GRP linings whether caused by defective materials or
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workmanship. The guarantee shall be valid from the date of completion of the installation
and must be handed to the Engineer before the issue of the Final Completion Certificate.
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20 All manholes shall be watertight on completion and where leakage is discovered the
Contractor shall perform such work and provide all materials as are necessary to render such
faulty work watertight. The Contractor is warned that he should expect rubbish and debris to
be deposited in the manholes during the course of construction and he should take the
necessary measures to ensure that the manholes clean.
21 Backfilling around manholes in roads shall be carried out using granular material as
4.5.2 Manholes for Surface Water Sewerage
1 Bases and mass concrete manholes shall be cast using Grade 40 SRC concrete. Where
reinforced concrete manholes are specified they shall be constructed in accordance with the
drawings and have a GRP liner complying to Clause 4.4.1. The GRP liner shall extend to
300mm above the soffit of the outlet pipe of the manhole. The inner surface above the GRP
liner shall have an epoxy protective coating.
2 The benching and channels shall be GRP lined as Clause 4.4.1.
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3 The underside of the base and the sides of insitu concrete bases and walls shall be protected
with a membrane tanking system as Clause 4.4.1.
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4 Precast Grade C50 SRC concrete manhole rings may be used above the level of the GRP
inner liner. The precast rings shall have a factory applied epoxy protective coating to all
surfaces.
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5 Cover slabs shall be precast using Grade 50 SRC concrete and shall have a factory applied
epoxy coating to all surfaces.
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6 The Contractor shall provide the Engineer with a 10 year unconditional guarantee against
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failure of all GRP linings whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be handed
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over to the Engineer before the issue of the Final Completion Certificate.
7 Ladders in structures where shown on the drawings shall be fabricated in stainless steel
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Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
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stainless steel.
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4.5.3 Chambers
1 The Contractor shall prepare a standard record sheet for every chamber for valves, meters,
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inspection, washouts and other similar purposes for the approval of the Engineer.
2 Chambers shall be constructed in accordance with the Contract Drawings and at the
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locations or at other locations directed by the Engineer.

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3 The Contractor shall ensure that there is a minimum clearance of 300mm around all flanges
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and parts of valves built into chambers, including the handwheel.

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4.5.4 Connections to Existing Pipelines
1 At locations shown on the Contract Drawings or as instructed by the Engineer, the Contractor
shall connect the new pipelines to the existing pipelines or structures but not until the said
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pipelines have passed the final tests.
2 The Contractor shall co-ordinate with Drainage Affairs, Maintenance Department staff to
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make connections onto existing foul sewers and other drainage pipelines.
3 The Contractor shall be responsible for dealing with all flows while making connections to
existing sewers or drainage pipework by over-pumping the entire flow between manholes or
other approved bypassing methods. The Contractor shall retain a standby pump and fulltime
operator on site during pumping operations.
4.5.5 Anchor and Thrust Blocks
1 The Contractor shall construct anchor and thrust blocks at every bend and junction on
pressure pipelines and where otherwise shown on the Contract Drawings or instructed by the
Engineer. Each thrust block shall to have a sufficient bearing area and shall be placed to
safely transmit thrust to the surrounding original ground. If soft, spongy, unstable or similar
material is encountered upon which the thrust block is to bear this unsuitable material shall
be removed and replaced with Grade 20 SRC mass concrete as directed by the Engineer.
2 The excavation for the thrust block shall be carried out prior to laying the pipes except that a
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trimming margin of not less than 150mm shall be left to be removed by hand excavation in
order to obtain a firm thrust face against undisturbed ground. This trimming margin shall only
be removed after laying and jointing of the pipes and the concrete for the thrust block shall be
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placed on the same day as the removal of the trimming margin.
3 No pressure shall be applied to thrust blocks until the concrete has matured for at least
seven days.
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4 "Rocker" pipes shall be installed adjacent to all concrete thrust blocks.
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4.5.6 Property Connections Survey
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1 The Contractor shall complete and submit to the Engineer for approval a standard record
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sheet of every property connection. The information shall be recorded on forms provided by
the Engineer.
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2 The Contractor shall survey and prepare individual plans for each property at a scale of 1:500
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(or such other scale as may be agreed by the Engineer’s Representative). These shall show
existing plot boundaries, location of all buildings, location of all visible services and location
and level of all drainage services, including septic tanks. The plans shall indicate the nature
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of each building, clearly identifying kitchen, mess areas, toilets, washrooms and the drains
serving these areas and gullies elsewhere. The plans shall identify the drains serving. The
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plan shall be submitted on paper and AutoCAD compatible .dwg file. As a separate layer on
the dwg file the Contractor shall mark his proposals for the property connection, including a
cross-section and this shall be submitted to the Engineer’s Representative for approval. No
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property connection work shall commence before approval to the proposed layout has been
received in writing from the Engineer’s Representative.
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3 In special cases only, an inspection chamber may serve more than one service connection.
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Locations of inspection chambers and the layout of service connections shall be as approved
by the Engineer.
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4 Service connections shall be laid at sufficient depths to allow for adequate gradient being
continued throughout the properly drainage system without the pipelines becoming too
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shallow for adequate cover to be provided over the pipe.
4.5.7 Future House Connections

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1 During the course of the Contract the Engineer’s Representative and the Contractor shall
agree on a programme regarding the positions and other details of the junctions to be left for
future house connections. Such branches and junctions shall in all cases terminate in an
approved stopper obtained from the pipe manufacturer.
2 The Contractor shall survey and prepare individual plans for each plot at a scale of 1:500 (or
such other scale as may be agreed by the Engineer’s Representative). These shall show
existing boundary walls or fences and ground level at each corner of the plot. The plan shall
be submitted on paper and AutoCAD compatible dwg file. As a separate layer on the dwg file
the Contractor shall mark his proposals for the property connection and this shall be
submitted to the Engineer’s Representative for approval. No property connection work shall
commence before approval to the proposed layout has been received in writing from the
Engineer’s Representative.
3 The Contractor shall produce accurate records of the exact location of all service connections
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and shall include for these in his rates.
4.6 TESTING OF PIPELINES
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4.6.1 General
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1 The Contractor shall submit for the Engineer's approval details of his proposed methods and
programme for testing (including details of test equipment) and shall arrange for all test to be
witnessed by the Engineer or other person appointed by the Engineer. Test equipment shall
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be approved by the Engineer and calibration certificates when requested by the Engineer
shall be submitted. The Contractor shall provide all equipment necessary for carrying out
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testing and cleaning including pumps, gauges, piped connections, stop ends, and all other
temporary works. All water required for testing and cleaning the pipelines shall be from a
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source approved by the Engineer.
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2 Pipelines shall be adequately restrained before being put under test except as hereinafter
detailed. No testing will be permitted until seven days after thrust blocks and other holding
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down works have been completed. Trenches may not be left open at joints before testing
pipelines except as permitted by the Engineer who may lay down certain restricting
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conditions. In addition to any tests of individual joints or other interim tests which may be
designated elsewhere, the Contractor shall submit all parts of the pipelines to a final test.
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3 This and the following Clauses on testing pipelines do not apply to GRP pipes for which
testing requirements are given in the Project Specification where appropriate.
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4 Pipelines shall be tested in lengths between manholes or valve pits with lengths not
exceeding 400 metres except by agreement with the Engineer’s Representative. Testing
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shall not be against closed valves, and pipes of different diameters shall not be tested
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together in the same test. The arrangements for testing a pipeline shall include provision for
purging the air from the pipeline during the test.
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5 In all pipelines which are constructed with mechanical joints or with joints which permit axial
movement, the joints shall be left open so that they may be inspected during hydraulic
testing. In such cases only the barrels of the pipes shall be backfilled prior to hydraulic testing
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taking great care to avoid the joints and leaving sufficient space all round the joints to permit
inspection and to undertake remedial measures should the joint be found to leak under
hydraulic testing. After the successful completion of hydraulic testing, the joints shall, if
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specified, be wrapped, coated or sleeved as appropriate, and then backfilled in the manner
specified elsewhere in this specification.
6 The final test shall be applied in the presence of the Engineer’s Representative.
7 The Contractor shall keep a record of all tests in a book which shall be available for
inspection and handed over to the Engineer’s Representative on demand. The Contractor
shall complete standard test record sheets as provided by the Engineer.
8 The section under test shall be properly sealed off with blank flanges or special stop end
caps held securely in position by adequate temporary anchorages, and filled with water. All
peak points of the pipeline shall be adequately vented during the filling operation using
temporary bleed valves. All air valves shall be removed and all other valves shall be set in the
open position.
9 Pipe joints, valves and fittings shall be checked carefully for loose bolts or connections which
might cause leakage and delay the execution of the tests.
10 Should any section fail to pass the tests, the Contractor shall determine the cause of the
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failure and shall locate, excavate and repair any damage or leakage sustained by the pipeline
before or during the tests and retest the section. The cost of such repair work, additional
backfilling and reinstatement and abortive tests shall be borne by the Contractor.
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11 Water for the test shall be disposed of in a manner to be approved by the Engineer.
Pumping water onto the site shall not be permitted.
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12 The Contractor shall be responsible for ensuring that all test methods and procedures comply
with his Health and Safety Plan.
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13 The Contractor shall provide detailed method statements for his methods of testing access
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shafts, manholes and pipelines.
4.6.2 Gravity Sewer Pipelines

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1 Each pipeline 600 mm or less in diameter shall be tested by air test. Should any pipe fail the
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air test, the Engineer may order a water test to be carried out. Acceptance of the pipeline will
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then be based on the results of the water test. All pipelines up to and including 1200 mm
shall be tested by air test in accordance with the requirements of BS EN 752.
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2 The Contractor shall, at his own expense, furnish all equipment and materials for making the
tests. Each pipeline shall be tested before backfilling and also after backfilling before carrying
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out road reinstatement or laying new road surfacing. Where the pipeline is located under a
new road alignment, the pipeline will be tested after sub-base compaction in complete. All
pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be
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clean and empty at the time of testing. Tests shall be performed in the presence of the
Engineer.
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(a) Air Test:

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(i) the Contractor shall plug all pipe outlets with suitable plugs, and brace each plug
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securely where needed

(ii) air shall be pumped in slowly to the pipe until a pressure of 100 mm water gauge
is indicated on a manometer connected to the system. After the internal
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pressure of 100 mm water gauge is obtained, 5 min shall be allowed for the air
temperature to stabilise within the pipe.
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(iii) Air may be added to restore the pressure to 100 mm water gauge. During a
further period of 5 min, the pressure shall not fall below 75 mm water gauge
without further pumping.
(b) Water Test
(i) all the joints of the pipeline shall be able to withstand a pressure of a minimum
5m head of water, above the crown of pipe at the highest point of pipeline
without leakage. A layer of embedding soil equal to the diameter of pipe shall
be laid over the pipe to prevent the lifting of pipe while applying test pressure.
However, all the joints shall be left open for the purpose of inspection for
leakage if any. All branches and open ends shall be closed with stoppers,
secured with longitudinal braces/thrust block, before testing begins
(ii) water shall be filled from the lowest point and air allowed to escape through an
air vent fixed for the purpose at the high points of the pipeline section under test.
The diameter of air vent shall be about one and half times the diameter of water
inlet pipe to allow easy escape of air. No entrapped air shall remain in the
pipeline while testing
(iii) a pressure of 5 m head of water shall be maintained for one hour to allow initial
absorption of water. After that the test pressure shall be maintained for 15 min
and water added shall be measured. If water consumption in 15 min does not
exceed 0.1 l/m2 of wetted inner pipe surface and if there are no visible leakage
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through joints, the pipeline shall be treated as passed.
(c) Infiltration Test
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(i) the upper ends of the sewer and service connections shall be closed sufficiently
to prevent the entry of water and pumping of groundwater shall be discontinued
until the groundwater surface reaches its natural level before beginning the
infiltration test the dewatering system shall be stopped, but not be removed until
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the infiltration test has been successfully completed or as otherwise permitted by
the Engineer the infiltration shall not exceed 6 litres per millimetre diameter per
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kilometre per day of the portion of sewer being tested, including the length of
service connection entering that section.
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(ii) the total length tested in one section shall not exceed 400 m in length. This
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length is dependent upon the type of deflection measuring equipment proposed
by the Contractor if flexible pipes are used.
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(iii) no gravity pipeline will be accepted if the total infiltration exceeds the above
mentioned limit and joints will not be accepted if during an internal inspection,
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any infiltration is visible.

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3 Prior to issue of a Certificate of Completion a CCTV survey shall, on the instruction of the
Engineer’s Representative, be carried out on a representative sample of no more than 12%
of the length of constructed pipelines. Should this survey indicate sections of pipeline which
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fail to meet the specification requirements, the Contractor will be required to carry out
remedial works and undertake additional CCTV surveys at his expense.
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4.6.3 Pressure Pipelines

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1 The pipeline shall be tested between valve chambers or into sections not exceeding 400 m in
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length unless approved otherwise by the Engineer. The section tests shall be carried out as
follows:
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(a) each pipeline or section thereof shall be filled with water and all air removed as far as
possible
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(b) the pressure shall then be raised by pumping in water until the test pressure is
reached and shall be maintained at this level by further pumping until it is steady
(c) pumping shall then be stopped and the time taken for the observed pressure to fall by
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1.0 m shall be recorded
(d) pumping shall then be resumed and the quantity of water pumped in order to restore
the test pressure shall be recorded
(e) if after three hours the test pressure has not fallen by 1.0 m, pumping shall be
resumed at that stage, the time being recorded as three hours
(f) the rates of loss shall then be calculated as the recorded quantity divided by the
recorded time
(g) the test pump and gauge shall be connected to the pipeline at a location other than
the highest point in the pipeline to facilitate release of air from the highest point
(h) the test pressure shall be such that the entire pipeline or section being tested is
subjected to 1.5 times the working pressure, 1.25 times the maximum surge pressure
or 800 kPa, whichever is the greatest
(i) the loss shall not exceed 0.02 litres per mm diameter per kilometre per 24 hours for
each 0.1 MPa of head applied
(j) if the pipeline fails to pass the test, the faults shall be located and repaired and the
pipeline retested until it passes the pressure test. All exposed pipe, fittings, valves
and joints shall be visually inspected during the tests.
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2 When all sections have been joined together after completion of section testing, unless
otherwise directed by the Engineer, the entire pipeline shall than be subjected to final test as
follows:
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(a) all joints between individual test sections shall be left uncovered during this final test
(b) the final test shall be carried out using the same procedure as the section test
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(c) in all cases of water tests, where the measured leakage rate exceeds the allowable,
the Contractor shall, at his own expense, make all necessary repairs and carryout
additional testing until a satisfactory result is obtained
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(d) before pressure testing is started the Contractor shall recheck pipes and valves for
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cleanliness and shall recheck the operation of all valves. The "open" ends of the
pipeline or sections thereof) shall normally be stopped off by blank flanges or cap
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ends additionally secured where necessary by temporary struts and wedges. All
anchor and thrust blocks shall have been completed and all pipe straps and other
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devices intended to prevent the movement of pipes shall have been securely
fastened
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(e) since valves cannot be guaranteed to be perfectly drop-tight, testing against closed
valves which are connected to an existing system shall be prohibited; testing against
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other closed valves (including air valves) not so connected, may be attempted if
desired, provided the valves are suitably anchored against thrust. No claims
whatsoever will be entertained on account of leaking valves, or any other difficulties
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in closing off lengths of pipework for testing, which shall be entirely an obligation of
the Contractor
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(f) on successful completion of the final test, the exposed joints shall be covered and the
trench backfilled as specified in the appropriate Clause 2.3 of this Section.
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3 The pipeline shall be tested for a period of at least 24 hours after which the test pressure
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shall be restored by pumping and the quantity of water lost during the test measured.
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4 Plastic irrigation drip pipe work shall be completely filled with water and visually inspected for
leakage. No section showing signs of leakage will be accepted. In addition, any length of pipe
which in the opinion of the Engineer or his designated representative is showing signs of
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degradation through contact with sunlight shall be cut out and replaced.
4.6.4 Other Pressure Pipelines

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1 Water Pipelines and Other Pressure Piping Carrying Liquids
(a) water pipelines and other pressure piping carrying surface water ground water and
treated sewage effluent excluding raw sewage pressure pipelines having socket and
spigot gasket joints shall be given a pressure and leakage test. Ductile iron or
PVC-U pipe shall be tested to AWWA C066 ; steel pipe to AWWA C066
(b) PVC-U treated sewage effluent pipework shall completely filled with water and
visually inspected for leakage. No section showing signs of leakage shall be
accepted.
2 Pressure Pipe, Flanged or Welded Joints
(a) PVC-U, steel, cast iron, ductile iron or other pipe material, with solvent welded,
welded, threaded, flanged, grooved end or flexible couplings and joints shall be
pressure tested. No leakage shall be permitted.
3 Pressure Air and Gas Piping:
(a) All piping carrying air or other gasses under pressure shall be given a pressure test.
No leakage is permitted. Low pressure air piping shall be tested pneumatically. Air
pressure of 140 kPa shall be applied to piping and fittings. High pressure air piping
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shall be tested to 1400 kPa. There shall be no drop in pressure in a 24-hour period
(b) Leaks shall be located and repaired to the satisfaction of the Engineer. Pressure
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drops due to thermal contraction are acceptable if the pressure returns to the original
test pressure after 24 hours.
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4 All piping, including valves, shall be field tested at the specified pressure with duration of two
hours minimum, for each pressure test. Piping conveying liquids between process tankage,
not subject to pumping, shall be tested to the maximum possible pressure that can be
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obtained under static conditions. Air piping shall be tested using air or nitrogen.
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5 All exposed pipe, fittings, valves, hydrants, and joints shall be carefully inspected before
either being cast in concrete or during the open trench tests, or both. All defects discovered
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shall be corrected by removal and replacement, as approved by the Engineer, and the work
then retested to demonstrate satisfactory performance.
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6 Where practical, no concrete encasement or backfilling of pipe joints will be permitted before
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the satisfactory completion of the tests in any given section.

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4.6.5 MDPE and HDPE Pressure Pipelines
1 Upon substantial completion of the pipeline or major sections, the line shall be cleaned and
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hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior
to commissioning. Testing shall be performed in accordance with the Finnish Standard SFS
3115:E and the procedure described below. The Contractor shall supply all necessary fittings,
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equipment and facilities required to undertake the testing.

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2 The Contractor shall prepare a detailed Method Statement for the pressure test that shall
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follow the outline test procedure described below and be subject to the approval of the
Engineer.
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(a) Seal the pipeline. Fix all blank flanges. Remove air valves. Remove all on line
equipment that may be damaged by high pressure.
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(b) Only test against blank flanges, do not attempt to test against closed valves.
(c) Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints
exposed where practical.
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(d) If backfilling is not practicable schedule the tests for early morning or evening.
(e) Fill the pipeline from the lowest point. Bleed the air from all high points and flange
points where it is possible and tighten once water begins to spill.
(f) When the line is full, close off the filling valve and check all flanges and the small
diameter test pipework for leaks.
(g) Phase1
Commence raising the pressure at the filling point to the operating pressure or a
pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and
add water whenever the pressure drops by 0.2 bar in order to maintain a steady
pressure.
(h) Visually inspect the pipe length for leakage.

(i) Phase2
After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar,
whichever is higher, as quickly as is practical. Again maintain this pressure for two
hours by adding water whenever the pressure drops by 0.2 bar.
(j) Visually inspect the pipe length for leakage.
(k) Phase3
At the end of the second two hours release the pressure back down to the phase I
level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes
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and as quickly as is practical, in a controlled manner.
(l) Phase3–Case1
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If after one hour the pressure in the pipelines remains at or above the operational
pressure, the test is considered to be completed with the pipeline passing the
hydrostatic test.
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(m) Phase3–Case2
If after one hour the pressure in the pipeline has fallen below the operational pressure,
water shall be added to raise the pressure back to the operating pressure level, having
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first noted the low pressure before adding any water.
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(n) Phase3–Case2
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce
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pressure to the previously recorded low value and save the water bled off). The
measured quantity is then compared against the allowable quantity to determine if the
pipeline passes the hydrostatic pressure test.
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Figure 1 Graphical Representation of the Hydrostatic Test Process

Case 1 – Pipeline passes test without adding any make up water
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Figure 2 Graphical Representation of the Hydrostatic Test Process

Case 2 – Water to be added to determine if the pipeline passes or fails
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3 If during Phase 3 the pressure within the pipeline remains at or above the operational
pressure of the pipeline for a period of at least one hour, the pipeline is considered to have
passed the hydrostatic test.
4 If water needs to be added the pipeline is considered to have passed the hydrostatic test if
the quantity of water added in terms of litres of water per km of pipeline length per hour of the
phase 3 period is less than that given in the following expression and in Figure 3.
Q ≤ Di/50 – 1 (litres / km/ hour)
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Q = added water in litres.
Di = internal diameter for the pipeline in mm.
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Figure 3. Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water
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Hydrostatic Test
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Pass
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5 The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be
connected to the feed pipework.
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6 The small diameter test pipework shall include a bleed valve at upper end of the pipeline and
at all high points together with feed pipework and valve at the lower end of the pipeline. The
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feed pipework shall include a means of draining off the water in to a measuring cylinder that
shall have a capacity of at least 2 litres capacity, graduated to 100 mls.
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7 The Contractor shall also have a thermometer for air and water temperature measurement.
8 Care should be taken not to over pressure the lower end of the system during testing.
Gauges should always be placed at the lower end of the length under test. As far as possible
the difference between the lower and upper end should be kept to one bar. It is recognized
that this may not always be possible when longer lengths are being tested, or where the
slope of the pipeline makes it impractical.
9 Where the phase II pressure is within the pressure rating of the pipe and test temperatures
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are 30 C or less no adjustment of test pressure is necessary.
10 When ambient temperatures at the time of test are over 30ºC and test pressures are over the
pressure rating of the pipe then it may be necessary to modify the test pressure according to
the table below or as agreed with the pipe manufacturer.
Test Temp.
O 32 38 43 49 54 60
( C)
Multiplier 0.9 0.8 0.75 0.65 0.6 0.5
11 When undertaking the testing the Contractor shall also take in to account the following points.
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(a) Care should be taken that any mechanical elements on the system are protected from
elevated pressure or completely removed from the pipeline.
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(b) Do not subject the line to prolonged over-pressure. Always aim to complete the
procedure within one working day.
(c) During the summer make sure that the pipe is not subject to direct sunlight during
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testing.
(d) During pressure testing pay full attention to the HSE aspects of the procedure. In
particular keep the general public away from high pressure test areas.
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(e) The test equipment must be capable of pressurizing the test length within a reasonable
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time. If the procedure becomes protracted (beyond one working day) the test length
may be modified or reviewed. Extremely long test lengths may be subject to special
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procedures.
4.7 MISCELLANEOUS ITEMS

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4.7.1 Manhole Covers and Frames

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1 Manhole covers shall be made from ductile iron and comply with BS EN 124 which shall
include:
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(a) Documentation confirming EN 29002 certification; or

(b) Documentation identified under Annex A to BS EN 124, concerning Independent Third
Party Inspection.
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(c) Independent random sample testing at an approved testing facility to demonstrate full
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compliance with all aspects of the code i.e. load testing and dimensional tolerances.
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(d) Production facilities shall be quality assessed in accordance with ISO 9000 or EN
29002 (BS 5750).
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2 Where manholes are located in road carriageway, the covers shall be non-rock double
triangular Class D400 unless otherwise designated. The double triangular cover shall be
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loosely coupled with stainless steel bolts. The frames for sewer and surface / ground water
manholes shall provide a minimum access opening of 750mm square. The frames for TSE
chambers shall provide a minimum access opening of 675mm square.
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3 Manhole covers in paved areas, car parks, verges, roads within property boundaries, and
other areas accessible to pedestrians and light vehicles, shall be non-rock double triangular
Class B125 unless otherwise designated. The double triangular covers shall be loosely
coupled with stainless steel bolts plate. The frames for sewer and surface / ground water
manholes shall provide a minimum access opening of 750mm square. The frames for TSE
chambers shall provide a minimum access opening of 675mm square.
4 All castings shall be grit blasted and coated on all exposed faces with a zinc primer and coal-
tar epoxy paint finish in accordance with Part 8 of this Section which shall result in a smooth
coating, tough and tenacious when cold, and neither tacky nor brittle.
5 The covers and frames on foul sewers shall incorporate a removable self-sealing GRP or
similar corrosion resistant plate meeting the requirements of Part 7 of this Section. The plate
shall fit between the cover and the frame such that no surface area of the frame shall be
exposed to the atmosphere within the manhole. This shall be achieved by the inclusion of a
neoprene sealing ring or by a similar approved method. The plate shall be complete with a
lifting handle on the upper surface. The design of the frame and cover and plate shall be
subject to the approval of the Engineer. A heavy grease seal is to be formed in all cases
between the cover and frame to prevent the ingress of sand.
6 Manhole covers for sewerage, surface water and treated sewage effluent systems shall have
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the following words embossed in both English and Arabic, respectively:
(a) Sewerage: Drainage
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Foul Sewer
(b) Surface water: Drainage
Surface Water
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(c) Treated sewage effluent: Drainage
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Treated Sewage Effluent.
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7 The size of lettering shall be approved by the Engineer.
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The Contractor shall supply one pair of manhole keys or prying and lifting bar, as appropriate
with each 30 covers provided with a minimum of one tool for each type cover. Keys and
prying and lifting bars shall be of approved appropriate design to match the different cover
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configurations. Keyways in manhole covers shall be of the closed type.

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9 Any manhole covers and frames on sewer or surface / ground water manholes that are
damaged or otherwise disturbed during the execution of the Works shall be replaced with
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covers and frames with a minimum clear opening of 750mm square and incorporate a GRP
sealing plate. If the opening through the concrete cover slab is less than 750mm square, then
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the concrete slab shall also be replaced.
10 Manhole covers for foul sewerage, surface water and treated sewerage effluent shall be
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provided with inscriptions both in Arabic and English cast into the top surface of the cover.
The lettering shall conform to the details given elsewhere in these documents or to the
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current details available from Drainage Affairs.

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4.1.2 Duct Covers and Frames

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11 Duct covers and frames shall be of cast iron, galvanised mild steel or aluminium as shown on
the Drawings, and shall be waterproof, non-rocking and recessed for filling with concrete.
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12 Cast iron duct covers and frames shall be obtained from an approved experienced
manufacturer, shall have machined seating faces and sloping mating faces to facilitate sliding
out of covers. The covers shall be capable of withstanding a 5 tonne wheel load when the
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recesses are filled with Grade SRC 25 concrete, or such other load as may be shown
elsewhere in the Contract Document.
13 Galvanised steel covers and frames shall be obtained from an approved experienced
manufacturer. Covers shall have solid bases fitted with reinforcing rods and where detailed
on the drawings shall incorporate locking bolts. Covers shall be capable of withstanding a 5
tonne wheel load when filled with Grade SCR 25 concrete, or such other load as may be
shown elsewhere in the Contract Document. Covers shall generally be filled with concrete,
but finished with tiling to match the surrounding floor finish.
14 Aluminium duct covers and frames shall be fabricated from aluminium alloy Grade 6063-T6
or other such chemically resistant alloy which the manufacturer can demonstrate will
withstand aggressive atmospheres likely to be encountered. Covers shall have solid bases,
and shall incorporate reinforcing bars held in place in plastic clips. Those faces of the frame
which will come into contract with cement mortar or concrete shall be painted with two coats
of bituminous paint before installation of the frame.
15 All covers shall be installed strictly in accordance with the manufacturer’s instructions.
16 Two complete sets of lifting keys including any necessary spanners shall be provided in each
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room in which ducts covers are installed.
17 A heavy grease seal is to be formed between the cover and frame to prevent the ingress of
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sand.
18 Multiple covers shall have removable intermediate beams.
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4.7.2 Hinged Aluminium Access Covers
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1 Hinged aluminium access covers shall be fabricated from chequer or ribbed plate. The
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covers shall be designed to carry a uniformly distributed load of 7.5 kN/m , and deflection
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under this loading shall not exceed one percent of the span.
2
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The frame shall be made from aluminium alloy complying with BS 1474 Grades 6063-T6 or
6082-T6.
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3 Where a cover is to be located within tiled areas, the frame shall be made from channel
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sections. The outer vertical arm of the channel frame shall be set flush with the top of the
adjacent floor finishes. The inner vertical arm shall be shorter to allow the chequer plate to sit
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the inner arm, while allowing the chequer plate cover to be flush with adjacent floor finishes.
The edges of the chequer plate cover shall be turned down into the channel section. Hinges
shall not stand proud of the cover and sealed lifting eyes shall be provided complete with two
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lifting keys for each cover.
4 Where a cover is to be located on concrete upstands or flat concrete surfaces, the frame
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shall be made from angle sections. The edges of the chequer plate cover shall be turned
down over the angle frame to provide a weatherproof cover. A lifting handle shall be provided
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on the edge opposite the hinges and a hasp provided for locking the cover with a padlock.
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The frame shall be bolted down to the concrete below using a minimum of four 10 mm
diameter stainless steel acrylic resin anchors.
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5 Fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy from
other material.
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4.8 FUTURE SEWER CONNECTION

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4.8.1 General
1 All stub pipes and pipes built into manholes for future connections are to be sealed with an
approved stopper, obtained from the same manufacturer as the pipe.
2 Marker posts shall be provided at the ends of all pipes left for future connection except where
a single stub pipe is built into a manhole and are to be located as directed by the Engineer’s
Representative.
4.9 INSITU LINING OF EXISTING MANHOLES
4.9.1 General
1 Where directed by the Engineer, the Contractor shall apply a GRP lining to all internal
surfaces of an existing manhole. The lining shall generally comply with the requirements of
Specification Clause 4.4.1.
2 The cover slab and manhole cover shall be removed. The slab shall be disposed to an
approved tip. The manhole cover and frame shall be thoroughly cleaned, treated with two
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coats of bituminous paint and submitted to Drainage Affairs Store.
3 All surfaces to be lined shall be clean and dry, step irons and any unsound materials shall be
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removed to the satisfaction of the Engineer prior to the commencement of any lining or
sealing work.
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4 For walls a preformed liner sized to fit in the existing manhole may be used. The joint
between the base of the liners and existing benching shall be sealed into a chase cut into the
existing benching by a heavy duty epoxy resin based sealant approved by the Engineer,
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which must be applied strictly in accordance with the manufacturer's instructions. The space
between the existing internal concrete wall of the manhole and the liner shall be filled using
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an approved non-shrink cementitious grout.
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Alternatively an in situ wall lining may be used. The walls shall first be made good with 3:1
sand cement mortar and the surfaces to be lined shall be lightly abraded. An in-situ lining
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6mm deep in compliance with Specification Clause 4.4.1.9 shall then be formed.
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6 On completion of the lining a new GRP ladder shall be installed in accordance with
Specification Clause 4.4.1.15, if shown on the Contract Drawings.
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7 A new cover slab and manhole cover shall be provided. The cover slab shall comply with
Specification Clause 4.4.1.9. The manhole cover and frame shall comply with Specification
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Clause 4.6.1.
8 The Contractor shall provide the Employer with a 7-year unconditional guarantee against
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failure of all GRP linings whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be handed to
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the Engineer before the issue of the Certificate of Completion.

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END OF PART
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Part 05: Valves, Penstocks and Appurtenances
5 VALVES, PENSTOCKS AND APPURTENANCES ....................................... 3
5.1 GENERAL ...................................................................................................... 3

5.1.1 Scope 3
5.1.2 References 3
5.1.3 Submittals 4
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5.2 MATERIALS .................................................................................................. 6
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5.3 SLUICE VALVES ........................................................................................... 7
5.4 BUTTERFLY VALVES ................................................................................... 8
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5.5 REFLUX VALVES .......................................................................................... 9
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5.6 PLUG VALVES ............................................................................................ 10
5.7
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SURFACE BOXES ...................................................................................... 10
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5.8 VALVE OPERATING TEE KEYS................................................................. 11
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5.9 AIR VALVES ................................................................................................ 11

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5.10 PRESSURE CONTROL AND RELIEF VALVES.......................................... 11

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5.10.1 General 12
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5.10.2 Pressure Reducing Valves 12

5.10.3 Pressure Relief Valves 12
5.10.4 Pressure Regulating and Sustaining Valves 12
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5.11 PENSTOCKS ............................................................................................... 12

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5.11.1 General 12
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5.11.2 Cast Iron Penstocks 12

5.11.3 Stainless Steel Penstock 14
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5.11.4 Plastic Penstocks 14

5.11.5 Stoplogs 15
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5.12 OPERATING DEVICES ............................................................................... 15

5.12.1 Lifts 15
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5.12.2 Liftnut 16
5.12.3 Gear Lift 16
5.12.4 Handwheel 16
5.12.5 Stem Covers 16
5.12.6 Actuators 16
5.13 FLAP VALVES ............................................................................................. 17
5.13.1 Flap Valves (General Purpose) 17
5.13.2 Flap Valves for Sea Water Applications 17
5.14 MISCELLANEOUS VALVES AND APPURTENANCES .............................. 17

5.14.1 Ball Float Valves 17
5.14.2 Globe Valves 18
5.14.3 Quick Coupling Valves 18
5.14.4 Emitters 18
5.15 FITTINGS .................................................................................................... 18
5.15.2 Flanges, Gaskets, and Bolts 18
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5.16 MECHANICAL COUPLINGS ....................................................................... 18
5.16.1 Grooved End Couplings 19
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5.16.2 Flexible Couplings 19
5.17 FLOW CONTROL ........................................................................................ 19
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5.17.1 Vortex Flow Control Devices 19
5.18 INSTALLATION AND TESTING .................................................................. 20
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5.18.1 Installation 20
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5.18.2 Testing M 20
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5 VALVES, PENSTOCKS AND APPURTENANCES

5.1 GENERAL
5.1.1 Scope
1 This part includes the specification for the manufacture, testing and supply and installation of
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valves, penstocks and appurtenances complete with frames, supports, anchor bolts, stems,
stem guides and other appurtenances.
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This Section
Part 1, General
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Part 4, Pipe Installation
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Part 6, Miscellaneous Metal Works
Section 1, General
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Section 9, Mechanical and Electrical Equipment
Section 10, Instrumentation Control and Automation.
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3 All valves are to be fixed to the pipelines with adaptor flanges for easy removal or installation.
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5.1.2 References

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ANSI B18.2.1..............Square and Hex Bolts and Screws

ANSI B18.2.2..............Square and Hex Nuts
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ASTM B62 ..................Composition Bronze or Ounce Metal Castings

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ASTM D256 ................Test Methods for Impact Resistance of Plastics and Electrical
Insulating
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Materials
ASTM D570 ................Test Method for Water Absorption of Plastics
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ASTM D638 ................Test for Tensile Properties of Plastics

ASTM D648 ................Test Method for Deflection Temperature of Plastics Under Flexural
Load
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ASTM D695 ................Test Method for Compressive Properties of Rigid Plastics

ASTM D696 ................Test Method for Coefficient Linear Thermal Expansion of Plastics
ASTM D790 ................Standard Test Methods For Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials
ASTM D1784 ..............Specification for Rigid Polyvinylchloride) (PVC) Compounds and
Chlorinated Polyvinylchloride (CPVC) Compounds
ASTM D2000 ..............Classification System for Rubber Products in Automotive Applications
AWWA C500 ..............Metal-Seated Gate Valves

AWWA C501 ..............Cast-Iron Sluice Gates

AWWA C507 ..............Ball Valves 150 mm Through 1200 mm
AWWA C510 ..............Double Check Valve Backflow-Prevention Assembly.
BS 4772......................Ductile iron pipes and fittings

BS 5163......................Predominantly key-operated cast iron gate valves for water works
purposes
BS 970 Part 1 .............General inspection and testing procedures and specific requirements
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for carbon, carbon manganese alloy and stainless steel
BS 2872......................Copper and copper alloy forging stock and forgings
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BS 2874......................Copper and copper alloy rods and sections (other than forging stock)
BS 3416......................Specification for bitumen based coatings for cold application
BS 4164......................Specification for coal-tar-based hot-applied coating materials
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BS EN 593..................Butterfly valves
BS EN 598 ------- Face-to-face valve dimensions
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BS EN 1092................Flanges and their joints M
BS EN 1171................Cast iron gate valves
BS EN 1561................Flake graphite cast iron
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BS EN 1563................Founding. Spheroidal graphite cast iron

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BS EN 1982................Copper alloy ingots and copper alloy and high conductivity copper
castings
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BS EN 3196................Nuts, hexagonal, self-locking in heat resisting steel

BS EN 12334..............Cast iron check valves for general purposes
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ISO 9000 ....................Quality Systems

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5.1.3 Submittals
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1 The Contractor shall obtain Engineer’s approval of submittals before placing order for the
following items.
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2 Valves. Complete data for the supply and installation of all valves and appurtenances shall
be submitted as follows:
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(a) Product data:

(i) for each type and model of valve, provide
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 assembly instructions,
 preventative/corrective maintenance instructions
(ii) for each actuator, provide
 currents at the specified voltage corresponding to locked rotor,
 maximum seating torque,
 average running load, and speed and full information concerning actuator
dimensions and weights shall be provided
(iii) identification of valves and accessories by tag numbers, where applicable.
(b) The following detailed written procedures shall be submitted to supplement the above
data:
(i) installation procedures for fixing, supporting, and anchoring valves
(ii) test procedures for adjusting and testing valve assemblies.
3 Penstocks:
(a) Complete fabrication, assembly, foundation, and installation drawings, together with
detailed specifications and information covering performance and materials of
construction, power drive assembly, devices, and other accessories shall be
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submitted as follows:
(i) Shop drawings, data and specifications for the equipment shall include, but not
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limited to:
 anchor bolt placement in the concrete structure including projections from
concrete or other surfaces
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 gate size, model numbers, opening sizes, elevations, locations, and
materials of construction
 stem sizes including details of connections, thread directions, and stops, and
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calculations for stem diameter and operators
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 stem guide details and locations
 gear box types, model numbers, and ratios, including connections furnished
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for each type
 wall thimbles
 motor data, including the motor manufacturer; minimum guaranteed
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efficiency and power factor at full load, 3/4 load, and 1/2 load; locked rotor
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current in amps; full load current in amps; motor speed in rpm; and mounting
details
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(ii) Factory Test Reports:

 Before shipment of any material specified herein, the Contractor shall submit
the results of all test reports for the approval of the Engineer.
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4 Operations and Maintenance Manuals:

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(a) The Contractor shall submit five copies of complete operation and maintenance
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manuals for penstocks and valves written in English in accordance with Part 1 of this
Section. Required operation and maintenance data shall include, but not limited to
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(i) complete, detailed written operating instructions for each product or piece of
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equipment. Manuals must be specific to the products supplied herein and the
application and operating conditions in Qatar. General manuals will not be
accepted
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(ii) complete, detailed preventative maintenance instructions

(iii) a complete inventory of all parts and components
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(iv) recommended spare parts lists and sources of supply for the parts
(v) all safety instructions relating to operation and maintenance procedures
(vi) name, address and phone number of manufacturer, manufacturer's authorised
service representative
(vii) troubleshooting instructions.
1 Valves, penstocks and appurtenances shall be supplied by approved manufacturers as

designated in the Project Specification. Production facilities shall be quality assessed in
accordance with ISO 9000 or equivalent.
1 Packaged items shall be stored in their original packing and wrappers until ready for
inspection by the Engineer. After inspection, all packaged items shall be repacked and
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rewrapped such that the items are sealed to the satisfaction of the Engineer, and stored until
ready for use or installation.
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2 Valves and appurtenances shall be stored off the ground, protected from dirt and moisture,
and protected from foreign material entering the ends.
3 All equipment shall be stored and handled in such a manner to protect equipment, finishes,
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and coatings, both internal and external.
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4 During storage, gates for penstocks shall be placed in a position to support and prevent
warping of gates and stems.
5.2 MATERIALS
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1 Cast iron shall conform to BS EN 1561 minimum Grade 250 unless otherwise specified.
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2 Ductile iron shall conform to BS EN 1563 unless otherwise specified.

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3 Aluminium bronze shall conform to BS 2872 Grade CA 104

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4 Bronze shall conform to ASTM B62 Grade 1, except that the maximum zinc allowance shall
be seven percent and the maximum aluminium allowance be two percent, unless otherwise
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specified.
5 Gun metal shall conform to BS EN 1982 Grade LG2

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6 Stainless steel shall conform to BS 970 Grade 316 S 31 unless otherwise specified.
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7 Duplex stainless steel shall conform to BS EN 1.4507 unless otherwise specified.

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8 Manganese steel shall conform to BS 970 Pt 1 Grade ISO M19.
9 Anchor bolts, assembly bolts, screws, nuts, and washers, including anchor bolts used in the
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installation and assembly of each unit shall be stainless steel unless otherwise specified, and
of ample size and strength to safely withstand forces created by operation of the unit while
subject to the hydrostatic heads described herein. The quantity and size of fasteners shall be
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as recommended by manufacturer, and as approved by Engineer. All bolt heads and nuts
shall be hexagonal. Anchor bolts shall be furnished with two nuts each to facilitate
installation and alignment.
10 All hand wheels, headstocks, foot brackets, guide brackets and thrust tubes shall be cast
iron. All other materials for valves, penstocks and appurtenances shall be as specified for
each item.
11 Unless otherwise stated Cast iron valves, penstocks and appurtenances shall be prepared
and painted in accordance with part 8 of this Section.
5.3 SLUICE VALVES

1 These specifications are applicable to all sizes of sluice valves larger than 80 mm diameter.
Sluice valves shall be of the following types.
(a) Potable and treated sewage effluent - 80mm diameter up to and including 300mm
diameter, to BS 5163 with resilient seating.
(b) All other uses other than (a) above, 80mm diameter up to and including 1,000mm
diameter to BS EN 1171metal seated.
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2 Valves shall be of the double flanged cast iron wedge-gate type unless otherwise stated.
Valves shall be cast iron body with renewable gun metal faces on body and wedge and bolt-
on cast iron bonnet. All exposed valves shall be of the rising stem type unless otherwise
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specified or shown on the Contract Drawing. Rising stem valves shall also incorporate a
combined yoke. Valves shall close clockwise.
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3 Valves pressure ratings shall equal the class of pipe unless otherwise indicated on the
Drawings.
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4 Valve stems shall be of stainless steel SS316 S31, machined all over, with a machine cut
robust trapezoidal or square form thread, operating in gunmetal.
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Stem seals on valves of 350mm diameter and above shall be of the stuffing box and gland
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form arranged for easy replacement of packing and seal and shall be accessible for
maintenance without removal of the valve from service. Stem seals on valves below 350mm
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diameter may be stuffing box and gland or 'O' ring. If 'O' ring seals are provided they shall be
arranged such that they can be replaced without removal of the valve from service. If 'O' ring
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stem seals are provided, the Contractor shall provide with the valve, two replacement sets of
rings labelled with the project number, manufacturer, valve model reference and size of
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valve.
6 Valves shall be provided with suitable handwheels as follows:

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(a) diameter shall be adequate for the duty required

(b) gearing shall be supplied where necessary to ensure that the required operating force
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applied by hand to the rim of the wheel does not exceed 250N (25Kgf)
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(c) Handwheels shall have smooth rims and the direction of closing, which shall be
clockwise, shall be cast on them.
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7 The following shall apply to spindles :

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(a) where possible and providing the valve is not subject to submergence, spindles shall
be of the non-rising type and a cast iron bridle piece, or similar, shall be incorporated
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on valves of the rising spindle type for this purpose.

(b) for valves of 300mm bore and above, and for all motorised/actuated valves spindles
shall be of the rising type. Thrust tubes shall be provided between the valve and
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headstock in order to absorb the thrust in both direction of operation. Thrust tubes
shall incorporate all necessary fixings brackets and spindle guide plates. Headstocks
shall incorporate a valve position indicator.
(c) where rising stem valves are subject to submergence the extension spindle shall also
be of the rising type with the threaded portion positioned above top water level.
(d) extended spindle installations shall include all necessary brackets, intermediate
supports etc.
(e) where extended spindles require to be operated at open flooring level, spindle guides
or guide brackets shall be provided close to flooring level.
(f) all spindles shall be of stainless steel Grade 316S31 and shall be compliant with the
requirements for valve stems.
8 Extension spindle couplings shall be of the muff type and shall be drilled with a nut and bolt
for securing the spindle to the valve stem, which will likewise be drilled to accept the bolt.
9 Vandal and weatherproof clear polycarbonate tube covers shall be securely fitted to protect
the threads of rising stems and spindles. Tubes shall be clearly and permanently engraved
to indicate the position of the valve.
10 Where valves are required to be operated by tee keys, spindle caps shall be fitted. The caps
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shall be drilled and each provided with nut and bolt for securing to the spindle which shall
likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied complete
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with operating tee key. The extended spindle shall be such that the tee key will be operated
at 0.9 to 1.2 m above floor level.
11 Where sluice valves above 350 mm bore are mounted with the spindle in the horizontal
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plane, valve bodies shall be fitted with renewable gunmetal machined gate slides and the
gates with renewable hard bronze shoes accurately machined to reduce sliding fraction.
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12 All sluice valves above 500 mm bore (300 mm if power actuated) shall be provided with
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jacking screws. Valves above 350 mm bore where mounted in a horizontal pipeline shall be
provided with feet. M
5.4 BUTTERFLY VALVES
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1 Butterfly valves shall comply with BS EN 593 and be of the double flanged, non-wafer,
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double eccentric (Offset) type. The valves shall be designed such that the body and disc seat
rings can be easily replaced.
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2 Valves shall be suitably designed to protect the disc edge from the effects of corrosion and
erosion.
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3 The valve body ends shall be double flanged and the flange dimensions shall comply with the
relevant requirements of BS EN 1092. The body shall be manufactured from close grained
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cast iron lined with rubber unless otherwise specified. The body parts shall be circular and
the diameter not less than that of the nominal pipe bore. The valve body shall be provided
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with suitable lifting lugs.

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4 The disc shall be designed to withstand the maximum pressure differential across the valve
in either direction of flow. The disc shall be contoured to ensure the lowest possible
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resistance to flow and shall be suitable for throttling operation. Disc material shall be duplex
stainless steel.
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5 The shaft shall be designed to withstand the maximum torque that will be imposed by the
operator. It may be in one piece or attached as two stub ends on opposite sides of the disc.
The stub end shall be of polygon profile type conforming to P3G or P4C. The means of
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attachment of the shaft to the disc shall be by using fixings in a homogeneous corrosion-
resistant material of a pattern which precludes the assembly becoming loose in operational
service. Grub screws, pins (parallel or taper) or clamps shall not be acceptable. The shaft
material shall be stainless steel SS316 S31. Self-lubricating PTFE faced bearings with ‘O’
ring seals shall be provided.
6 The body seat shall be stainless steel SS316 S31 and the disc seat shall be one piece
moulded nitrile rubber. They shall be designed to be drop tight in either direction at
maximum differential pressure.
7 Valves shall be provided with suitable stops to prevent movement of the shaft beyond the
limits corresponding to fully open and fully closed position of the disc.
8 A suitable external locking device shall be provided on the non-drive shaft end, to enable the
geared unit to be removed with the valve remaining in service in the open or closed position.
9 Fasteners like nuts, bolts and washers of stainless steel shall be provided.
10 Unless otherwise specified each valve shall be provided with a suitable handwheel of
adequate diameter for the duty required and gearing shall be supplied where necessary to
ensure that the required operating force applied by hand to the rim of the wheel does not
exceed 25 kgf.
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11 Extension spindles, headstocks and foot brackets shall be provided where specified.
Headstocks shall incorporate a valve position indicator.
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12 The valve shall be closed by clockwise movement of an actuator or handwheel. Direction
arrows clearly indicating 'open' and 'closed' positions shall be provided on the actuator or cast
on the handwheel.
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13 Valves shall be provided with a position indicator to show the positions of the disc, mounted
on the driven shaft end.
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14 All Valves above 350 mm diameter shall be provided with lifting lugs or eye-bolts
5.5 REFLUX VALVES

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1 Unless otherwise specified Reflux valves shall be swing type, double flanged cast iron
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conforming to BS EN 12334. Flange dimensions shall comply with the relevant requirements
on BS EN 1092 PN16. Reflux valve shall have face-to-face dimensions in accordance with
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BS EN 558.
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2 The valves shall be of the quick acting single door type designed to minimise slam on closure
by means of heavy gunmetal-faced doors weighted as necessary. The valves shall be fitted
with renewable gunmetal door sealing faces which shall be positively fixed. The door hinge
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pin/shaft shall extend through a sealing gland on the side of the body and be fitted with an
external lever to permit back flushing.
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3 Glands shall be of the stuffing-box type with the exception that for valves below 450 mm bore
they shall be of the ‘O’ ring type.
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4 The valve door shall be weighted to suit the application and the lever shall be of the heavy
duty type designed for the additional of external weights should these be required at some
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future date.
5 Where there is a likelihood of surge pressures being generated reflux valves shall be of the
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low loss non-slam wafer type. They shall feature a spring action giving drip tight shut-off.
The movement of the sealing plate shall not lead to scuffing of the seat material.
6 All reflux valves shall be suitable for operating in the horizontal plane unless otherwise
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specified.
7 Cover plates shall be of sufficient size to allow easy hand access for cleaning and service
and shall be supplied complete with tapped bosses fitted with air release cocks.
8 Valves above 350 mm bore shall be provided with feet.
9 The design of the valve body shall be such that there is adequate clearance around and at
the back of the door to minimise jamming by rags and debris. Stops shall be provided to limit
the back lift of the door and shall be positioned to prevent fouling.
10 The hinge pin/shaft shall be stainless steel SS316 S31 and preferably square in section to
ensure positive location of the door. If circular shafts are utilised the back flushing lever shall
be located on a squared section, the diagonal dimensions of which shall be equivalent to the
full diameter of the shaft. Both door and lever shall be positively and securely fixed to the
hinge pin/shaft. Grub screws, pins (parallel to taper) or clamps will not be acceptable. All
internal fixing devices shall be of stainless steel SS316 S31.
11 Reflux valves fitted to the delivery side of pumps shall be fitted with balance weights to
minimise slam. If specified, they shall be provided with a totally enclosed proximity switch
operated by an external cam fitted to the extended spindle. The proximity switch shall be of
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the metal clad type with sealed actuator and cable entry. Cam operated micro-switches will
not be acceptable.
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5.6 PLUG VALVES
1 Plug valves shall be eccentric and equipped with resilient faced plugs and be of non-
lubricated type capable of handling abrasive and raw sewage. The plug valves shall have
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PN 16 flanged ends. Valves shall be furnished with manual operators as a unit. Each valve
plug shall rotate 90 degrees from the fully open to the tightly shut position and shall seat at an
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angle of 90 degrees from the pipe axis in which the valve is installed.
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2 Valves shall be satisfactory for applications involving throttling service and for frequent
operation after long periods of inactivity. Valves with operators shall be suitable for operation
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with flow in either direction.
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3 Valves shall be non-lubricated, with non-shock pressure differential acting in either direction;
at 175 kPa differential across the valve, the valve will provide drip-tight shut-off. Valves
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75 mm diameter and above shall have bolted bonnet design. Bodies shall be of high carbon
cast iron or nickel iron having 1 % to 1.5 % nickel content. Valves shall have raised seats
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and all surfaces in contact with the plug face shall have 90 % pure nickel or coating. Valves
shall have an average tensile strength of 240 MPa. Port areas of valves sizes greater than
100 mm shall be at least 75 % of full pipe area. Flanged valves shall be faced and drilled
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minimum PN 16 standard and shall have face-to-face dimensions of standard sluice valves.
Valves shall have balanced plugs to assure low torque and drip-tight shut-off.
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4 Valves shall be equipped with resilient plug facing to provide drip-tight shut-off without use of
sealing lubricants. Even if small solids are trapped between the plug and seat, the resilient
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facing shall provide tight shut-off and prevent seat damage. Resilient plug facings shall be
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neoprene, ethylene propylene terpolymer, or other suitable materials capable of handling

abrasives and raw sewage.
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5 Valves shall have heavy-duty upper and lower guide bearings capable of resisting corrosion
and lubricated by the liquid being handled.
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6 Valves shall be actuated by means of lever for valves under 80 mm in size and by enclosed
gear and handwheel operator for valves 100 mm and longer. All valves shall be supplied with
operators which required less than 10 N/m torque for operation. Chain wheels with guides
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shall be furnished on all valves located 2 m or more above floor levels with stainless steel.
7 Valves operating devices shall be as specified in Clause 5.12 herein.
5.7 SURFACE BOXES

1 Surface boxes and covers shall be adjustable cast iron of the slip type and fitted to the sizes
and depths of valves as shown on the Drawings. Covers and frames shall be heavy duty and
be suitable for wheel loads up to 11.43 tonnes.
2 Surface boxes shall be coated by dipping or other equivalent means using a hot applied coal
tar based material complying with BS 4164 or cold applied bitumen material complying with
BS 3416. No coating shall be applied to any casting until its surfaces are clean dry and free
from rust oil and deleterious material.
5.8 VALVE OPERATING TEE KEYS

1 Valve operating keys shall have a 50mm square socket. The length of the key shall enable
the valve to be operated with hands at waist height. Unless otherwise stated in the Contract
Documents one tee key per ten valves that are to be tee key operated, shall be provided for
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each site.
5.9 AIR VALVES
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1 Air and gas relief valves shall be of the double orifice pattern with grey or ductile cast iron
bodies. The inlet flange shall be faced and drilled in accordance with BS EN 1092 PN16. Air
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valves for TSE or potable water shall be of the water type. Air valves for all other waste
water work shall be of the sewage type.
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2 The valve shall be adequately sized for the release of gas from the pipeline (or other
container) without restriction of rate of filling or flow due to back pressure and also to allow
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admission of air during pipeline emptying at a rate sufficient to prevent excessive depression
of pressure in the pipe.
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3 Valves shall be designed to prevent the operating elements being in contact with the pipeline
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liquid by approved means such as the provision of an auxiliary float and chamber sufficiently
large to isolate the orifice valves and seats throughout the rated operational range.
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4 In applications where the pipeline characteristics may lead to liquid column separation with
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consequent possibility of surge a vented non-return valve shall be provided which allows air
to enter freely on separation but controls explosion of air/gas as the liquid column re-joins.
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5 In applications where the hydraulic conditions are such that pressures fall below atmospheric
pressure during normal operation and where air inflow at that time could induce surge
conditions, an air inflow check valve shall be incorporated.
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6 All air and gas relief valves and associated isolating valves shall be works tested and capable
of withstanding the same test pressures as the pipeline or vessel on which they operate.
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7 Air valves and operating linkages that are not made stainless steel shall be pure epoxy resin
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coated in accordance with Part 8 of this Section.
8 Air valves shall be vented wherever possible directly into the wet well. In cases where this is
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not possible the Contractor shall provide suitable odour removal for the air expelled from the
valve.
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9 Where air may be drawn into the valve that contains dust, sand etc. means shall be provided
for trapping/filtering this.
10 Air valves shall be installed in such a manner that routine maintenance can be carried out.
11 Air valves shall be fitted with an isolating sluice valves and gearing shall be provided where
necessary to facilitate operation.
5.10 PRESSURE CONTROL AND RELIEF VALVES

5.10.1 General
1 The valve body shall be of cast iron conforming to BS EN 1561 with flanges conforming to
BS EN 1092 PN16 or BS 10. The valve shall be extra heavy construction throughout. The
valve interior trim shall be bronze as well as the main valve operation. All working parts shall
be easily removed from the valve body for ease of maintenance. All controls and piping shall
be of non-corrosive construction.
5.10.2 Pressure Reducing Valves
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1 Pressure reducing valves shall maintain any desired downstream-delivery pressure for which
the reducing pilot valve is adjusted provided the upstream head does not drop below a
determined head. During low flow conditions, a resilient rubber valve seat shall ensure drop
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tight sealing. The valve shall be completely piped ready for installation.
5.10.3 Pressure Relief Valves
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1 Pressure relief valves shall maintain constant upstream pressure by bypassing or relieving
excess pressure, and shall maintain close pressure limits without causing surges. The main
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valve shall be a hydraulically operated, diaphragm-actuated, globe or angle pattern valve. It
shall contain a resilient, synthetic rubber disc. The downstream pressure setting shall be
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adjusted by compression of the spring via the adjusted screw.
5.10.4 Pressure Regulating and Sustaining Valves

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1 Pressure sustaining valves shall open and close in modulating action as required to maintain
constant system pressure. On pressure reversal valve shall close tightly. Operation shall be
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completely automatic with only one adjustment required to change the pressure setting.
Adjustable pressure range from 1.0 bar to 8.5 bar. The valve shall be "Y" pattern globe
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diaphragm actuated with pilot control. The diaphragm shall be made of reinforced neoprene
and the pilot shall be bronze and all tubing copper.
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5.11 PENSTOCKS
5.11.1 General
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1 Each item of equipment shall be furnished and installed complete with all supports, anchor
bolts, stems, stem guides, and appurtenances ready for operation. All mechanisms and parts
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shall be amply proportioned for the stresses which may occur during operation or for any
other stresses which may occur during fabrication and erection. Individual parts furnished
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which are alike in all units shall be alike in workmanship, design, and materials and shall be
interchangeable. Penstock in sewage pumping stations shall be stainless steel/cast iron with
gun metal seating suitable for corrosive environment.
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5.11.2 Cast Iron Penstocks

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1 Penstocks shall be suitable for their application, and shall be installed and positioned in such
a manner as to allow ease of operation and maintenance.
2 Penstocks shall carry identification marks and brass name plates in accordance with BS EN
12334, which identify the penstock number and function.
3 Penstocks shall be clockwise closing.
4 Penstocks shall be watertight under the conditions stated for head and direction of flow.
5 All materials used in manufacture of the penstocks shall conform to the following minimum
standards unless otherwise specified:
Cast Iron BS EN 1561 Grade 250

Gunmetal BS 1400 Grade LG2
Aluminium Bronze BS 2872 Grade CA104
Stainless Steel BS 970 Pt. 1 Grade 316 S31
High Tensile Brass BS 2874 Grade CZ114
(Manganese Bronze)
Manganese Steel BS 970 Pt. 1 Grade ISOM19
Phosphor Bronze BS 2574 Grade P13
6 Fixing nuts and bolts supplied by the manufacturer shall be of stainless steel.
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7 Each penstock shall be provided with a suitable handwheel of adequate diameter for the duty
required. Gearing shall be supplied where necessary:
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(a) to ensure that the required operating force applied by hand to the rim of the wheel
does not exceed 250N (25Kgf)
(b) if the handwheel cannot be readily accessed, extension spindles, headstocks and foot
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brackets shall be provided where specified
(c) where possible, the extension spindle shall be of the rising type with the threaded
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portion position above top water level
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(d) headstocks for non-rising spindle installations shall incorporate a position indicator.
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8 Handwheels shall have smooth rims and the direction of closing which shall be clockwise
shall be cast on them. Vandal and weather proof clear polycarbonate tube covers shall be
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securely fitted to protect the threads of rising stems and spindles. Tubes shall be clearly and
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permanently engraved to indicate the position of the valve.
9 The frames and doors of cast iron penstocks shall be made from close grained grey iron.
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The penstocks shall be designed so as to ensure tight closure while maintaining freedom of
door movement during operation and minimising sliding wear of the sealing faces. They shall
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incorporate adjustable wedges or swivelling cams and actuating pegs manufactured from a
non-corrodible material.
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10 Headstocks and foot brackets shall be provided for non-rising spindle penstocks where the
latter are specifically called for. Guide brackets shall however be provided where necessary.
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Non-rising spindles shall be fitted with thrust collars and arranged so as to transmit the thrust
arising due to the operation of the penstock directly to the penstock frame. Where
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headstocks are required on non-rising spindle installations they shall incorporate a penstock
position indicator.
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11 Penstock spindles shall be of forged stainless steel SS316 S31 , machined all over, with a
machine cut robust trapezoidal or square form thread, operating in a gunmetal nut.
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12 Extension spindles shall be of stainless steel SS316 S31and shall be compliant with the
requirements for penstock spindles. Extension spindle couplings shall be of the muff type
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and shall be drilled and provided with a nut and bolt for securing the spindle to the penstock
spindle, which shall likewise be drilled to accept the bolt.
13 Extended spindle installations of the rising type shall be provided for valves of 300 mm bore
and above, and for all motorised/actuated penstocks. These shall be of stainless or
manganese steel or manganese bronze. Thrust tubes shall be provided between the
penstock from and headstock in order to absorb the thrust in both directions of operation.
Thrust tubes shall incorporate all necessary fixing brackets and spindle guide plates. All
handwheels, headstocks, foot brackets and guide brackets shall be of cast iron.
14 Where penstocks are required to be operated by tee keys, spindle caps shall be fitted. The
caps shall be drilled and each provided with nut and bolt for securing to the spindle which
shall likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied
complete with operating tee key. The extended spindle shall be such that the tee key will be
operated at 0.9-1.2 metres above floor level.
15 Where penstocks are provided with greasing nipples, these shall be fitted with extension
tubes to facilitate lubrication from a nearby walkway or other readily accessible location.
16 Non-ferrous metal sealing faces shall comprise accurately machined gunmetal or bronze
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strips bedded and fixed to machined recesses in the frame and door. The strips shall be
secured by non-corrodible countersunk screws. The faces of the strips shall then be brought
together in the operation position and hand scraped to a watertight finish.
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17 Handwheels, headstocks, foot brackets and thrust tubes shall be of cast iron.
18 Cast iron penstocks and headstocks shall be coal tar epoxy coated in accordance with Part 8
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of this Section.
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5.11.3 Stainless Steel Penstock
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1 Where indicated on the drawings or elsewhere in the Contract Documents, penstocks for use
in aggressive environments shall be manufactured from corrosion resistant materials as
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follows:
(a) Metal parts exposed to the atmosphere shall be manufactured from stainless steel to
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BS 970 Part 1, Grade 316 S31.
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(b) The frame shall be fixed to the wall using nuts and bolts Grade 316 S31 stainless
steel.
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(c) The door of the penstock shall be manufactured from corrosion resistant plastic or
stainless steel (Grade 316 S31). Plastic shall also be totally resistant to ultra-violet
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light. Asbestos shall not be used in any filling materials within plastic gates.
(d) The seals used on corrosion resistant penstocks shall be suitable for the medium in
which the penstock is immersed. Flexible rubber seals shall not be used on penstocks
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immersed in raw sewage for example, where sharp objects and grit may destroy the
seal at the high velocities experienced when opening and closing the doors.
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2 All other requirements shall be as specified in Clause 5.11.2 herein.

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5.11.4 Plastic Penstocks

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1 Plastic penstocks shall be of the flush invert type and the underside sealing face shall consist
of high resilient material securely bonded into a channel or similar section forming the invert
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of the frame into which the bottom of the door shall effect a watertight seal.
2 The door of plastic penstocks shall be made from sheets of approved rigid cellular polymer
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sandwiched between sheets of approved rigid compressed composite plastics. The linear
PVC or GRP materials shall be used. The doors thus formed shall have sufficient strength to
withstand the required working pressure without deflection or distortion that would affect the
operation of water-tightness of the penstock. Totally enclosed steel matrix shall be
incorporated in the door construction to ensure adequate rigidity.
3 The sealing faces and side guides shall be EPDM having a high resistance to sliding wear
and shall be to the approval of the Engineer. The sealing strips shall be securely fixed to the
inner faces of the frames and adjusting devices or other means of ensuring freedom of
movement without loss of seal shall be provided. The adjusting devices and fasteners shall
be of stainless steel conforming to BS 970 Part 1 Grade SS 316 S31.
4 Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra-high

molecular weight polyethylene material. The operating nuts for the spindle retaining blocks
shall be fixed in a visible position inside a separate gate lifting bracket bolted on to the top of
the door with stainless steel fasteners. The operating nut or spindle retaining block shall not
be contained within the door.
5 All plastic materials shall be non-toxic ultraviolet stabilised and shall have fire resistance as
specified in BS 475 and be to Class P and Class I of Part 5 and 7 thereof respectively.
6 All other requirements shall be as specified in Clause 5.1.3 Clause 5.11.2 herein.
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7 Plastic penstocks shall only be used when indicated in the Contract Documents and
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5.11.5 Stoplogs
1 Stoplogs shall be fabricated from reinforced composite plastic material which is non-toxic and
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stabilised against ultraviolet light. Asbestos shall not be used in the manufacture of the stop-
logs.
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2 Plastic logs of 300 mm and 400 mm depths shall be furnished to provide closure of stoplog
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openings. Full depth gates shall not be acceptable.
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Each log shall be provided with a stainless steel eye bolt at each end which fits into a recess
in the under surface of the next log. Two lifting poles fitted with hooked ends for engaging
the eye bolts shall be furnished for each facility and shall be mounted locally on a handrail
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supported pole rack. Poles and racks shall be constructed of aluminium and bolts of
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stainless steel.
4 Stoplogs shall provide a high degree of sealing with a leakage rate of less than 0.04 l/sqm of
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seating perimeter. Stoplog frame shall be for insertion in a wall and invert recess.
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5 Anchor bolts shall be stainless steel.
6 Frames shall be manufactured from stainless steel BS 970 or BS 1449 Grade 316. All frames
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shall be suitably reinforced and include corner gussets where necessary. All fasteners shall
be stainless steel.
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7 Frames shall be fitted with seals which are molecularly incompatible with the closure
material. Where necessary, the seals shall be fixed with corrosion resistant retaining strips
and stainless steel fasteners.
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5.12 OPERATING DEVICES

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5.12.1 Lifts
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1 Lifts shall be designed to operate the gate of the specified head with a maximum of 25 kg
force applied to the device. The lift shall be a liftnut for tee key operation or gear/handwheel
lift as designated.
5.12.2 Liftnut
1 The liftnut shall be hexagonal, gunmetal and internally threaded to fit the stem. The housing
shall be cast iron and suitable for mounting in the head angle, gate frame extension or wall
mounted bracket. The liftnut shall be flanged to maintain position in the housing and to
accommodate the thrust developed during gate operation. Each lift shall be furnished with a
bronze stop nut. The nut lift shall accept a T-bar operator or handwheel. Suitable T-bar
operators shall be furnished.
5.12.3 Gear Lift
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1 The gear lift mechanism if required shall be of the crank operated type with either a single or
double gear ratio, depending on the lift load. Each type shall have a cast bronze liftnut
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threaded to fit the operating stem. Ball thrust bearings shall be provided above and below
the flange on the liftnut to take the load developed in opening and closing the gate. Gears
shall be of cast iron or steel, accurately machined with cut teeth, and smooth running with
suitable shafts running in gunmetal sleeve bearings or roller bearings of ample size. All
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geared lifts shall be suitable for auxiliary motor operation. All gears and bearings shall be
enclosed in a cast iron housing. Fittings shall be provided so that all gears and bearings can
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be periodically lubricated. The removable cast iron crank shall be fitted with a rotating
handle. The lift mechanism shall be supplied with a cast iron pedestal, machined and drilled
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to receive the gear housing and suitable for bolting to the thrust tubes, operating floor or wall
bracket. The maximum crank radius shall be 400 mm. The direction of rotation to open the
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gate shall be indicated on the lift mechanism. A cast iron stop nut shall be provided for each
lift. All exposed cast iron shall be coated according to Part 8 of this section.
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5.12.4 Handwheel
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1 The housing shall be cast iron and shall be suitable for mounting on the head angle or pipe
frame extension. The lift nut shall be flanged to maintain position in the housing and to
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accommodate maximum thrust developed during gate or valve operation. The lift nut shall
be bronze and internally threaded to mate the stem. Each lift shall be furnished with a bronze
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stop nut. The steel or cast iron handwheel shall have a solid rim and shall be smooth and
free of sharp edges and an arrow and the work "OPEN" shall be cast in the rim or attached to
the handwheel. Handwheels generally shall be positioned on a headstock 750 mm above
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operating level.
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5.12.5 Stem Covers

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1 Stem covers shall be provided on all valves or gates with rising stems. Stem covers shall be
clear butyrate with Mylar decals indicating open and close gate position and of sufficient
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length to totally enclose the stem when the gate is fully open. The top shall be closed and
the bottom shall screw into a cast iron housing mounted on top of the gate operator. The
inside of this housing shall be bored to the exact diameter of the stem cover to assure
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accurate alignment of the cover.
5.12.6 Actuators
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1 Actuators are specified in Section 21.

5.13 FLAP VALVES
5.13.1 Flap Valves (General Purpose)
1 The seat shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with a raised
section around the perimeter of the waterway opening to provide the seat. The raised
section shall provide a seating plane diverging, top to bottom, from the plane of the mounting
flange to assist in positive closure of the cover. The seat shall be shaped to provide two
bosses extending above the top of the waterway opening for mounting the top pivot lugs.
Pivot lug bosses shall be drilled and tapped for mounting studs. The flap shall be designed
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to be either butted to the face of a wall or to the outlet flange of a discharge pipe. The flaps
shall be operable at a head of 10 m.
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2 The cover shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with
necessary reinforcing ribs, with a lifting eye for manual operation, and with bosses to provide
a pivot point connection with the links. Bosses shall be designed to place the hinge bolts in
double shear when gate is assembled.
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3 Each pivot lug shall be one-piece cast iron. Lugs shall have double bosses to place the top
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hinge bolts in double shear when they are assembled through the links. The lugs shall be
adjustable in the horizontal plane without removal of the cover from the gate links. The
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adjustment shall allow the top pivots to be moved toward the gate seat for reduced sensitivity
of the cover, or moved away from the gate seat to provide opening with a minimum
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differential head. Two studs shall be used to connect each pivot to the gate seat.
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4 The links connecting the cover and pivot lugs shall be one-piece heavy duty cast iron. Each
link shall be provided with bronze bushings at each pivot point. The bottom of the links shall
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be provided with an adjusting screw to properly align seating faces on the cover with respect
to the seat. The links shall be designed to limit the double hinge action, preventing the cover
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from rotating sufficiently to become wedged in the open position.
5 Cast iron work shall be coated before delivery with a bituminous compound as specified in
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Clause 8.5.16.2 of QCS.
5.13.2 Flap Valves for Sea Water Applications

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1 Flap valves frames including fixings for sea water and other aggressive applications shall be
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of stainless steel conforming to BS 970 Part 1. Sealing faces shall be phosphor bronze
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conforming to BS 2874.
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2 Flap valves manufactured from corrosion resistant materials will also be acceptable for
general purpose applications.
3 Flap valves above 1500 mm square shall be of the double door type.
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4 Doors shall be of reinforced natural rubber compound of sufficient flexibility to maintain an

efficient seal under minimal seating head conditions.
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5 Door hinges shall be continuous across the full width of the door and manufactured from
homogeneous polypropylenes, polyurethane or similar non-ageing material.
5.14 MISCELLANEOUS VALVES AND APPURTENANCES
5.14.1 Ball Float Valves
1 Ball float valves shall comply with BS 1212. Flanges shall conform to BS EN 1092.
2 PVC ball valves 50 mm and smaller shall be of the true union socket weld type, and valves
75 mm and larger shall be of the flanged type. Valves shall be rated at 1000 kPa at 50 °C
unless otherwise specified.
3 Metal ball valves 60 mm and larger shall have brass balls with carbon steel bodies, and
valves 50 mm and smaller shall have brass bodies. Valves shall have a Teflon seal and
seat. Valves shall be rated at 1000 kPa at 100 °C unless otherwise specified.
4 Stainless steel ball valves shall be flanged with stainless steel body, ball and stem. Valves
shall be rated at 1000 kPa at 100 °C unless otherwise specified.
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5.14.2 Globe Valves
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1 Globe valves shall be low-zinc bronze body type with tapered discs permitting close
regulation of flow. Valves 75 mm and larger shall be flanged, Class 125 conforming to ANSI
B16.1 in drilling and dimensions. Valves 60 mm and smaller shall be 1,000 kPa, and shall
have screwed joints.
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5.14.3 Quick Coupling Valves
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1 Quick coupling valves shall be of robust construction consisting of a cast bronze body and
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dust cap with machined bronze valve cage and seat. The valve washer shall be neoprene
rubber with stainless steel packing washer and fixing screw. The stem seal ring shall be
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neoprene rubber.
2 Double lug keys with swivel hose ells and standard 20 mm diameter hose connectors of the
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same manufacturer shall be supplied to the Employer’s stores at the rate of one key for every
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five hose points. Each part shall be cast or machined bronze with neoprene rubber seals.
The cost of supplying these keys complete shall be included in the rates for valves.
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5.14.4 Emitters
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1 Bubble emitters shall be brass with 12 mm BSP thread designed for adjustable flows.
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5.15 FITTINGS
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1 All flanges, fittings, coupling, valves, and appurtenances shall be rated for the pipeline
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pressure, except as noted on the Drawings.

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5.15.2 Flanges, Gaskets, and Bolts
1 Flanges shall be PN 16 rating or as otherwise designated. Flange gaskets shall be ring type.
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Thickness shall be 1.5 mm for pipes 250 mm and smaller, and 3 mm for larger pipes.
Flange assembly bolts shall be standard hexagon head machine bolts with heavy hot
pressed, hexagon nuts and shall conform to BS EN 1092. Bolt length shall be such that after
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the joints are made up, the bolts shall protrude through the nut, but not more than 12 mm. All
anchor bolts shall be stainless steel.
5.16 MECHANICAL COUPLINGS

5.16.1 Grooved End Couplings
1 Couplings shall engage and lock the grooved or shouldered pipe ends allowing some degree
of contraction, expansion, and angular deflections. Coupling housing shall be of ductile iron
or malleable iron and shall consist of two or more segments held securely together by at least
two steel bolts. Sealing gasket shall be of such design that internal pressure in the pipe
increases the tightness of the seal and shall be of materials suitable for the intended service.
The coupling shall have a rated working pressure not less than the pressure rating of the
pipe.
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2 Corrosion protection shall be applied in accordance with the requirements specified in Clause
5.16.2 herein.
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5.16.2 Flexible Couplings
1 Flexible (sleeve) couplings of the full sleeve type, split sleeve type, or flanged adapter type
shall provide the requisite pipe flexibility without jeopardising pipe joint integrity due to
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hydraulic thrust, and shall have the same pressure rating as the pipe. Couplings shall have
all metal bearing surfaces and shall be provided with galvanised steel bolts and nuts.
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Flexible couplings shall be restrained unless the Engineer has given his approval to omit this
feature for specific cases. Specific requirements for each type are as follows:
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(a) full sleeve type couplings shall be properly gasketed and shall be of a diameter to
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fit the pipe. Each coupling shall consist of a steel middle ring, two steel followers, two
gaskets, and the necessary steel bolts and nuts to compress the gaskets. Stepped
couplings of this general type shall be used when stepping from one pipe material to
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another of the same nominal diameter
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(b) split sleeve type couplings shall consist of one gasket, two housing clamps, and two
bolts and nuts to obtain the flexibility for connecting the piping. Steel shoulders shall
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be provided and welded to the pipe ends to accommodate the couplings

(c) flexible flanged coupling adapters shall be of the sleeve type, consisting of steel
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middle ring, steel followers, gaskets, and steel bolts and nuts to compress the
gaskets. The couplings shall contain anchor studs of strength adequate to hold the
pipes together under a pull equal to the longitudinal strength of the pipes.
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2 Couplings to be installed underground shall, in addition to any factory applied paint coating,
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site have one of the following corrosion protection systems:

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(a) hot pour moulding with enamel complying with BS 4164 type IV Grade 105/8, to give
a minimum of 20 mm thickness around all parts of the fittings
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(b) laminate tape coating after priming and profiling with mastic
(c) paint coating with high build coal tar mastic to give a minimum dry film thickness of
500 m in at least three coats.
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3 Step couplings used in force mains with flexible pipes shall be provided with a restraint
system where necessary to prevent longitudinal movement between the flexible pipe and the
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coupling. The restraint system shall be as shown on the Drawings or approved by the
Engineer.
4 No joints shall be coated until hydrostatic testing of the joints is successfully completed.
5.17 FLOW CONTROL
5.17.1 Vortex Flow Control Devices
1 Where indicated on the drawings or elsewhere in the Contract Documents, Vortex Flow
Control Devices shall be manufactured from corrosion resistant materials as follows:
(a) stainless steel to BS 970 Part 1, Grade 316 S31.

(b) the device shall be fixed using nuts and bolts of Grade 316 S31 stainless steel.
5.18 INSTALLATION AND TESTING
5.18.1 Installation
1 The Contractor shall obtain the necessary installation drawings from the manufacturer and
shall store, transport, handle and install the valves, penstocks, stoplogs, and appurtenances
in strict accord with the manufacturer’s drawings and recommendations. Care shall be taken
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during mounting of gates and logs to avoid warping the frames and to maintain clearance
between seating faces.
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2 All ferrous surfaces shall be finish coated in accordance with Part 8 of this Section.
5.18.2 Testing
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1 Factory Testing. Penstocks shall be factory-tested for a seat clearance check in accordance
with the applicable provisions of AWWA C501. Penstocks that do not conform with the
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testing requirements of AWWA C501 shall be made satisfactory or rejected and replaced.
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Before shipment of the gates, the Contractor shall submit certified copies of test reports to
the Engineer for review. M
2 Site Testing. Following completion of the installation of the penstock, the Contractor shall
furnish the services of the authorised representative of the manufacturer to adjust and
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operate the gates of directed by the Engineer. Adjustment shall be made so that the gates
operate smoothly, seat properly, and are installed to the tolerances recommended by the
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manufacturer. After the equipment has been tested and adjusted, the Contractor shall
perform a field leakage test on each gate in the presence of the Engineer in accordance with
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the applicable provisions of AWWA C501. Both seating and unseating heads shall be tested
as applicable. If any of the equipment fails to meet the above test, it shall be modified as
required and retested to conform with specifications, until the maximum allowable leakage,
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per AWWA C501, is not exceeded. Modifications or adjustments required to meet the test
shall not impair the smooth operation of the equipment.
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END OF PART
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QCS 2014 Section 08: Drainage works Page 1
Part 06: Miscellaneous Metal Works
6 MISCELLANEOUS METAL WORKS ............................................................. 2
6.1 GENERAL ...................................................................................................... 2

6.1.1 Scope 2
6.1.2 Reference 2
6.1.3 Submittals 2
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6.2 MATERIALS .................................................................................................. 4
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6.2.1 Steel 4
6.2.2 Stainless Steel 4
6.2.3 Aluminium 4
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6.2.4 Iron 4
6.2.5 Welded Anchor Studs 4
6.2.6 U Channel Concrete Inserts 4
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6.2.7 Concrete Anchors 5
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6.3 COATINGS .................................................................................................... 5
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6.3.1 Galvanising 5
6.3.2 Anodising 6
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6.3.3 Factory Painting 6
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6.4 FABRICATION AND ERECTION ................................................................... 7

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6.4.1 General 7
6.4.2 Staircases 8
6.4.3 Ladders 9
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6.4.4 Step Irons 10

6.4.5 Handrails and Railings 10
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6.4.6 Chequer Plate 11

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6.4.7 Gratings and Open Mesh Flooring 12

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6 MISCELLANEOUS METAL WORKS

6.1 GENERAL
6.1.1 Scope
1 This part includes the specifications for the design, fabrication and erection of ladders,
staircase assemblies, open mesh flooring, chequer plate, gratings, handrailing, step irons,
supports, anchors, and other appurtenances.
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2 Related Sections and Parts are as follows
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This Section
Part 1, General
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Part 7, Miscellaneous GRP Works
Section 1, General
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Section 16, Structural Metalwork
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Section 17, Metalwork.
6.1.2 Reference
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BS 970........... Wrought steels for mechanical and allied engineering purposes

BS 1470......... Wrought aluminium and aluminium alloys for general engineering purposes;
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plate, sheet and strips

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Drawn Tube
forging stock
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BS 1474......... Wrought aluminium and aluminium alloys for general engineering purposes -
bars, extruded round tube and sections
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BS 4211......... Specifications for permanent fixed ladders

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BS 4592......... Industrial type metal flooring, walkways and stair treads.

BS 5395......... Stairs, ladders and walkways
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BS 5493......... Code of practice for protective coating of iron and steel structures against
corrosion
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BS EN 1561... Founding Gray Cast Iron

BS EN 1563... Found spheroidal graphite cast iron
BS EN 1993... EURO code 3, Design of steel structures
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BS EN 13101. Manhole steps

BS EN ISO 2560 Welding consumables - Covered electrodes for manual metal arc welding
of non-alloy and fine grained steels
EN 124 .......... Gully tops and manhole tops for vehicular and pedestrian areas – Design
requirements, type testing, marking, quality control
ISO 9000 ....... Quality System
6.1.3 Submittals
1 The Contractor shall submit complete data as described below.

2 Product Data:
(a) the Contractor shall provide manufacturers’ specifications, load tables, dimension
diagrams, anchor details and installation instructions for products to be used in the
manufacture of metal fabrications.
3 Design Calculations and Shop Drawings:
(a) the Contractor shall provide design calculations and shop drawings for the
fabrication and erection of all assemblies of metal fabrication work which are not
completely shown by manufacturers’ data sheets, including anchorage and accessory
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items. Plans and elevations at metric scales not less than 1:10 scale, and details of
sections and connections at not less than 1:5 scale shall be included
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(b) detailed drawings shall show material type, thickness grade/class dimensions, and
construction scheme. The submittal shall include catalogue pages, erection
description, manufacturers’ data/instructions and templates.
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4 Where structural steelwork is to be provided the Contractor shall submit duplicate copies of
dimensioned shop drawings for approval by the Engineer’s Representative. If drawings are
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not approved, one copy shall be returned to the Contractor marked up indicating the
alterations required. Upon final approval one copy of the drawing, stamped ‘Approved’ by the
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Engineer’s Representative, shall be returned to the Contractor. Four further copies of the
approved drawings shall then be submitted to the Engineer’s Representative. No shop
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fabrication may commence before receipt of the relevant shop drawings.
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5 The shop drawings shall become record drawings on the completion of steelwork erection
and the original drawing and one ISO size A2 (495 & 420) negative of each shall be supplied
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to the Engineer. If there were any changes to the steelwork during erection these should be
supplied together with the original and the size A2 signed negative.
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6 WPS and PQR

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1 Fabricated metal products and materials shall be provided by experienced and approved
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manufacturers and fabricators as designated in the Contract document to the written

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2 Where welding/brazing is required the Contractor shall:

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(a) submit for approval welding procedure specification (WPS) and procedure qualification
record (PQR) in conformance with AWS D1.1(steel structures), ASME IX (piping and
pressure vessels) and BS EN 288 part 4 (Aluminium) and BS EN ISO 1101-8 (Iron) as
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appropriate;
(b) submit for approval welder qualifications which shall be in conformance with the above
codes and or BS EN ISO 9606-2 (aluminium alloys),
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(c) assign a CSWIP 3.1 or AWS QC qualified welding inspector, who shall be subject to
the Engineer’s approval, to witness all welding.
1 Metal works shall be stored off the ground, protected from moisture, until ready for use or
installation.
2 Metal works shall be stored and handled in such a manner to protect finishes.
3 Metal works shall be stored and handled to prevent bending under its own weight and
superimposed loads.
6.2 MATERIALS
6.2.1 Steel
1 Steel rolled shapes, plates and bars shall conform to the requirements of Section 16 unless
otherwise specified in this Part.
2 Bolts and nuts shall be of standard commercial quality steel conforming to Section 16, and
shall be galvanised when used with galvanised work.
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AWS D 1.1 - Steel Structure Welding Code
ASME VIII Div. 1 - Pressure Vessel welding
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ASME IX - Boiler & Pressure Vessel Code - Section IX Welding & Brazing
ASME B31.3 - Process Pipe
6.2.2 Stainless Steel
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1 Stainless steel shall conform to BS 970 and shall be Grade 316 S31 unless otherwise
designated.
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2 Stainless steel bolts, hexagonal cap screws, and studs shall be BS 970 Grade 316 S31
unless otherwise designated. M
3 All stainless steel to be welded shall be BS 970 Grade 316L.
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6.2.3 Aluminium
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1 All aluminium plate, pipe and structural shapes shall conform to BS EN 12020, and BS 1472
with BS EN 485 Grades 6036-T6 or 6082-T6 or such other chemically resistant alloy that the
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manufacturer can demonstrate to be suitable for use in aggressive atmospheres likely to be

encountered in sewage pumping stations. All aluminium items embedded in concrete shall
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have two coats of bituminous paint. Where aluminium surfaces are in contact with concrete
surfaces or with dissimilar metals, PVC-U gaskets shall be used to isolate the aluminium.
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6.2.4 Iron
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1 Ductile Iron. Ductile iron shall be in accordance with BS EN 1563.

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2 Grey Cast Iron. Cast iron shall be in accordance with BS EN 1561.

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3 Malleable Iron. Malleable iron shall be in accordance with BS EN 13101.
6.2.5 Welded Anchor Studs

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1 Headed anchor studs (HAS) or threaded anchor studs (TAS), as indicated on the Contract
Drawings:
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(a) Carbon Steel: BS EN ISO 898, either semi-killed or killed aluminium or silicon
dioxidation, unless indicated otherwise.
(b) Stainless Steel: BS EN ISO 3506, Grade SS 316, Condition CW, where indicated.
6.2.6 U Channel Concrete Inserts
1 Rolled: BS EN ISO 9445 Type 316 stainless steel, 2.7 mm thickness, 40 mm width by 35
millimetres depth, with stainless steel anchors at 250 mm maximum spacing, Styrofoam
fillers, and end cap.
2 Nut and Bolt Hardware: Type 316 stainless steel, 16 mm minimum diameter, unless
indicated otherwise. Manufacturer’s standard to match insert.
6.2.7 Concrete Anchors
1 For concrete anchor spacing less than 12 anchor diameters and edge distances less than
six anchor diameters, make reduction in allowable pullout and shear values.
2 Allow for thermal movement resulting from the maximum range in ambient temperature in
design, fabrication, and installation of handrails to prevent buckling, opening up of joints, over
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stressing of components, connections and other detrimental effects. Base design calculation
on actual surface temperatures of materials due to both solar heat gain and night time sky
heat loss. Temperature change is difference between high or low temperature and
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installation temperature.
3 Use approved service load allowable values for size, length, embedment, spacing, and edge
distance to match required loads shown in calculations.
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6.3 COATINGS
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6.3.1 Galvanising
1
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Galvanising shall be executed after all fabrication has been completed and shall be carried
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out in accordance with BS 5493:1977. The articles shall be pickled in dilute sulphuric or
hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They shall be
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thoroughly washed, stoved and dipped in molten zinc and brushed so that the whole of the
metal shall be evenly covered and the coating thickness after dipping shall not be less than
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the BS 5493 System Reference Number recommended for the particular conditions and in
any case not less than 85 microns.
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2 Unless otherwise specified, all ferrous metals shall be galvanised in conformance with
reference standards according to the nature of the work. Factory fabrication shall be
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complete before galvanising. Galvanised coatings that have been marred or damaged
during erection or fabrication shall be repaired using designated touch-up material.
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3 Surfaces of exterior units which have been galvanised after fabrication and are intended for
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bolted or screwed field connections shall not be welded, cut or abraded.

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4 Galvanised coatings marred or damaged during erection or fabrication shall be repaired

conforming to BS 5493 and in accordance with the coating manufacturer's instructions.
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5 Unpainted galvanized surfaces shall not be used in an immersed condition within three
months of hot dip galvanizing and/or before an adequate protective patina has formed.
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6 All mild steel parts unless otherwise stated, are to be heavily galvanised by the "hot dip"
process, or other methods as agreed by the Engineer, after fabrication. Where large units are
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concerned, an approved metal spraying process to BS specifications may be used subject to

the approval of the Engineer. With the exception of the metal flooring to be supplied
unpainted, the whole of the galvanised mild steel parts and metal sprayed parts are to be
treated with a zinc phosphate primer before leaving the place of manufacture. (No lead oxide
or iron may be used in priming the galvanised parts.) Painting shall be in accordance with
the Schedule A [Work Requirements], Part 5 [Warranted Project Data], 5.1 [Drawings] or as
selected by the Engineer.
7 All steel and ironwork of whatever kind to be galvanised shall be thoroughly de-scaled by shot
blasting to clear metal to BS 4232 second quality, to clean the surfaces of all dirt, weld
spelter, grease, slag, oil-paint or other deleterious materials, and immediately after is to be
galvanised by a hot dip process, followed by quenching in water. The molten zinc in the
galvanising bath shall contain not less than 98.5 percent of zinc by weight. All articles are to
be immersed in the bath only for a time sufficient for them to attain the temperature of the
bath and they are to be withdrawn at such a speed that a coating of 90 microns thickness is
achieved, or such other practicable maximum thickness for the article defined in BS 729, Part
"Hot dip galvanised coating on iron and steel." The galvanising is to be done in all cases after
machine work, chipping, trimming, filling, fitting, drilling or bending is completed. Every article
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is to be covered evenly on all sides.
8 The zinc coating shall consist of a uniform layer of zinc free from abrasions, creeks, blisters,
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chemical spots or other imperfections, and so applied that it will adhere firmly to the surface
of the steel.
9 The galvanising shall be applied in such a manner that the spelter will not peel off. The
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coating of the finished product shall be even, smooth and uniform throughout. Machine work,
dye work, cutting, punching, bending, welding, drilling, thread cutting and other fabrication
shall all be done, as far as practicable, before galvanising.
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10 The galvanising shall have no adverse effect on the mechanical properties of the articles so
treated. Variations in dimensional properties shall be kept to a minimum.
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11 The work of surface preparation and galvanising shall be carried out, for any one article, on
the same working day.
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12 Galvanising on steelwork where required is to be carried out after fabrication and assembly.
13 Light gauge metal work is to be galvanised by the hot dip process as specified in BS 3083 or
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BS 2989.
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14 Contact between galvanised steel members and aluminium surface is to be prevented by

means of a layer of "Densochrome" or similar approved tape.
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15 All necessary care and precautions are to be taken in shipping and transporting the
galvanised or metal sprayed units to avoid damage to the coating. Where damage proves to
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be extensive in the opinion of the Engineer, the whole unit shall be recoated.
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16 Where galvanised parts are to be bolted or riveted together, the joint shall be made with an
approved barium or zinc chromate paste.
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17 Where the metal parts are too big to be hot dip galvanised, approval of the Engineer shall be
sought for the steel parts to be shot blasted to BS 4232 second quality and then immediately
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zinc sprayed to a minimum thickness of 0.1 mm in accordance with BS 2569 Part 1.
6.3.2 Anodising
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1 All aluminium members shall be anodised after fabrication in accordance with Sections 16
and 17.
2 All aluminium and aluminium alloy materials shall be anodised after fabrication to a thickness
of grade AA 20 and subsequently sealed against corrosion. After anodising, the aluminium
surfaces shall not be painted but left self-finish. Anodising of aluminium shall comply with the
requirements of BS 1615.
6.3.3 Factory Painting
1 All protective coatings and painting shall be carried out as specified in Part 8 of this Section.
2 Before leaving the factory, ferrous metals not designated to be galvanised shall be given one
coat of primer as specified in Clause 8.2 of Part 8. Portions to be embedded in concrete or
masonry shall not be painted.
6.4 FABRICATION AND ERECTION
6.4.1 General
1 Stairs, ladders and walkways provided shall conform to BS 4211 and BS 5395.
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2 Fabrication and erection shall be performed by approved specialist subcontractors
experienced in work of equivalent magnitude. Shop drawings shall be prepared by the
Contractor based on the details shown on the Drawings. The Contractor shall
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(a) verify all measurements and shall take all site measurements necessary before
fabrication
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(b) be responsible for correctness of detailing, fabrication, and for the correct fitting of
structural members
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(c) not substitute sections
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(d) not modify connections.
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Members and connections, for any part of the structure, not shown on the Drawings shall be
the Contractor’s responsibility.
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3 The Contractor shall use materials of the size and thickness shown on the Drawings, or if not
shown, of the required size and thickness to produce adequate strength and durability in the
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finished product for the intended use.

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4 All work at the factory shall be preassembled to the greatest extent possible to minimise field
splicing and assembly of units at the Site. Units shall be disassembled only to the extent
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necessary to comply with transportation limitations and shall be clearly marked for
reassembly and proper installation. Ladders shall be supplied as preassembled units.
5 For the manufacture of metal fabrications which will be exposed to view, only materials which
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are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled
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trade names and roughness shall be used. Any such blemishes shall be removed by
grinding, or by welding and grinding, before cleaning, treating and application of finishes
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including anodising and galvanising. Smoothness shall be required all round for handrails
and ladders.
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6 Exposed work shall be formed true to line and level with accurate angles and surfaces and
straight sharp edges. Exposed edges shall be rounded to a radius of approximately 1 mm
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unless otherwise designated.
7 Exposed connections with hairline joints which are flush and smooth shall be formed using
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concealed fasteners wherever possible. Exposed fasteners shall be flat-head (countersunk)

screws or bolts. Bolt and screw holes shall be predrilled for attachment of metal fabrication
work and for the attachment of adjacent materials.
8 Welding shall be carried out by experienced tradesmen, and made with designated
electrodes or submerged arc conforming to BS EN ISO 2560. The following procedures shall
be carried out:
(a) before fabrication, all steel shall be thoroughly wire brushed, clean of all scale and
rust, and thoroughly straightened by approved methods that will not injure the
materials being worked on
(b) welding shall be continuous along the entire line of contact except where tack or
intermittent welding is permitted
(c) where exposed, welds shall be cleaned of slag and ground smooth.
(d) All stainless steel welding shall be gas tungsten arc welding (GTAW)or shield metal
arc welding (SMAW) processes using stainless steel type 316L consumables
conforming to the requirements of the under-mentioned codes / AWS A5.9 (GTAW) or
AWS A5.4 (SMAW).
(e) All aluminium welding shall be undertaken using GTAW process using consumables
under 5356 classification of AWS A5.10.
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(f) Welding to be undertaken in accordance with the applicable code as follows:
General guidance for arc welding BS EN ISO 1101 –1
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Arc welding of ferritic steels BS EN ISO 1101 – 2
Arc welding of stainless steels BS EN ISO 1101 –3
Arc welding of aluminium BS EN ISO 1101-4
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Welding of cast iron BS EN ISO 1101 -8
Steel Structures AWS D1.1
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Pressure vessels ASME VIII Div 1
Piping ASME B31.3
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9 Fixing shall be carried out as follows: M
(a) the Contractor shall fabricate and install anchoring devices with spacing as required
to provide adequate support for the intended use of the work
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(b) fastenings to wooden plugs will not be permitted

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(c) All nuts and bolts shall be threaded in accordance with BS 3643 “Isometric series
threads” part 2 “Limits and tolerances for coarse pitch threads” and fitted with 3mm
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thick washers beneath bolt and nut.

(d) Regardless of the materials being fixed all bolts, nuts, washers and anchor plates shall
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be of stainless steel Grade 316 S31 to BS 970 and shall remain unpainted. PTFE
washers shall be fitted beneath stainless steel washers for both bolthead and nut.
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(e) Drilled anchor fixings for use on concrete structure shall be of a type approved by the
Engineer’s Representative. The positions of all drilled anchors shall be approved by
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the Engineer’s Representative and any Contractor proposing to use such fixings shall
be deemed to have undertaken to supply, mark off, drill and fit.
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(f) All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be
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such that when fitted with a nut and tightened down, the threaded portion shall fill the
nut and not protrude from the face thereof by more then half the diameter of the bolt.
(g) All jointing material shall be provided by the Contractor.
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10 Dissimilar materials shall be separated by gaskets.

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6.4.2 Staircases
1 Metal staircases shall be constructed to the overall dimensions detailed on the Drawings and
shall be prefabricated in marine quality mill finished aluminium alloy or galvanised steel.
Staircases shall be designed to span longitudinally from wall to wall and shall be designed to
carry a live load of 5 kPa. Stringers shall be of adequate size to support dead and live loads.
2 Treads shall be of non-slip surface and shall have adequate stiffness to carry a point load of
1.8 kN at the centre.
3 Landings shall not exceed 3 m.

4 Kicker plates shall extend to a minimum of 100 mm above flooring and open sides. The
risers shall not exceed 200 mm.
5 Chequer plates shall be as specified in Clause 6.4.6 wherein.
6 Unless otherwise shown on the Contract Drawings, furnish flush type abrasive nosing on
stairs.
7 Nosing Components:
(a) Homogeneous epoxy abrasive, with minimum 50 percent aluminium oxide content,
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formed and cured upon an extruded aluminium base.
(b) Epoxy abrasive shall extend over and form curved front edge of nosing.
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(c) Base of Nosing: Extruded aluminium alloy, 6063-T5, heat-treated complying with BS
EN 12020.
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(d) Anchoring System: Double-set anchors consisting of two rows of integrally extruded
anchors.
(e) Size: 75 mm wide by 6 mm to 10 mm thick by length as shown.
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(f) Colour: Selected by Engineer from manufacturer’s standard colour range.
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6.4.3 Ladders M
1 Galvanised steel ladders shall be to the form and dimensions shown on the Drawings, and as
specified below:
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(a) ladders shall comply with BS 5395, Part 3.

(b) ladders greater than 6000 m shall be provided with an intermediate platform
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(c) stringers shall be solid flat sections of minimum size 65 mm by 13 mm where extended
stringers are provided they shall be radiused over the top for walk-through access and
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shall be not less than 600mm apart.

(d) fixing brackets shall be at maximum 2500 mm centres
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(e) rungs shall be

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(i) solid sections of minimum 20 mm diameter

(ii) at 300 mm centres
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(iii) minimum 380 mm wide between stringers

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(iv) minimum 200 mm from adjacent walls

(v) capable of withstanding a point load of 5000 N applied at the centre of the rung
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and close to one end

(f) when supported horizontally over a span of 1.0 m with the climbing face uppermost
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and with a load of 1000 N applied at the centre of the span, the ladder shall not
deflect more than 15 mm at the point of application of the load and shall show no
permanent deflection after removal of the load. Each ladder fixing shall be capable of
withstanding shear and pull-out loads of 5000 N
(g) safety cages shall be provided where indicated and where the distance between
landings exceeds 3500 mm. These shall be constructed of three vertical flat sections,
minimum size 50 mm by 8 mm supported by flat hoops with a diameter of 750 mm.
The hoops shall be at a maximum of 900 mm centres and the first hoop shall be
2400 mm above lowest platform level. No single hoop shall be used
(h) all welds shall be ground flush and smoothed and ladders hot-dip galvanised after
fabrication. Connections to concrete or masonry walls shall be secure with accurately
positioned stainless steel anchor bolts. Ladders shall be mounted to produce a
finished appearance that is plumb, straight and true to dimensions.
2 Stainless steel ladders shall generally be of dimensions as designated for galvanised steel
ladders except that all materials shall be of stainless steel.
3 Aluminium ladders shall be to the form and specified dimensions shown on the Drawings,
and as specified below:
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(a) the spacing of stringers, rungs and safety hoops shall be as galvanised steel ladders.
(b) material shall be aluminium alloy to BS EN 573 grade EN AW-6082.
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(c) ladders shall be of all welded construction. Stringers shall be drilled to receive rungs
which shall be welded into position from the outside of the stringers. Welds shall not
be proud of the outside of the stringers
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(d) rungs shall be of substantial section serrated tube to enable sure hand and foot holds
(e) fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy
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from other materials
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(f) all other requirements shall be as specified for galvanised steel ladders
(g) ladders shall be obtained from approved suppliers.
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6.4.4 Step Irons
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1 Step ironing rising main valve chambers shall be galvanised malleable cast iron, shall
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conform to BS EN 13101, and shall be of general purpose type. The tail length shall be 230
mm unless the well into which the tail is to be cast is less than 290 mm thick.
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2 Step irons in house connection chambers shall comply with BS EN 13101 and be the
general-purpose type manufactured of galvanised malleable cast iron. The tail length shall be
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115mm. The step irons shall be epoxy coated with a material compatible with a galvanised
surface and finished with a two part, acrylic polyurethane topcoat as detailed below and
applied in accordance with the manufacturer’s instructions.
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Epoxy Coating 50 DFT

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Two Part Acrylic Finish 50 DFT

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6.4.5 Handrails and Railings

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1 Handrailing shall be obtained from an approved experienced manufacturer and shall be

GRP, circular hollow section, marine quality mill finished aluminium alloy (BS EN 573 grade
EN AW-6082) in pre-fabricated lengths complete with fixings or shall be stainless steel
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circular hollow section (BS970 Grade316S31). Site welding will not be accepted. All welded
parts to be completed during manufacturing fabrication with approved WPS by Engineer in
accordance with Clause 6.1.4 of this Part. Handrails and railings fabricated from mild steel,
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stainless steel, or aluminium as shown on the Drawings and meet the following requirements:
(a) brackets, bolts and fastening devices shall be provided as required for
complete installation
(b) handrailing and railings shall be provided with smooth bends and welded joints
ground smooth and flush
(c) installed railings and supports shall withstand a 1100 N load applied at any point,
downward or horizontally or 740 N/m along the top rail, whichever is greater
(d) the deflection of both rails and standards shall to exceed 2 % of the span/height under
a horizontal load of 360 N/m on the top rail.
2 Galvanised steel handrailing shall be provided in accordance with the following requirements:
(a) stanchions shall have a nominal bore of 40 mm and a minimum wall thickness of
3.25 mm
(b) stanchions on steel stringers shall have base plates or angles welded to bottom of
pipe and bolted to stringer
(c) rails shall have a nominal bore of 32 mm and minimum wall thickness of 4 mm
(d) horizontal handrails shall be 1,100 mm high with an intermediate rail 550 mm high
(e) railings shall be
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(i) mounted so as to produce a finished appearance that is plumb, straight, and
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true to dimension, free from kinks, twists, and abrasions
(ii) curves, where indicated on the Drawings or necessary, shall be bent to a radius
of not less than 100 mm. Where shown on the Drawings, or directed by the
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Engineer, removable sections shall be provided
(f) toe plates shall be provided where railings are not mounted on stanchions
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(g) welds shall be ground flush and smooth and handrailing hot-dip galvanised after
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fabrication
(h) sleeves shall be provided for setting by other trades where embedded
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(i) connections to concrete or masonry wall surfaces shall be secure with accurately
positioned stainless steel anchor bolts, or with cinch anchors and bolts
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(j) where expanding anchor bolts are used on concrete surfaces, the bases shall be
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bedded on a mastic sealant as approved by the Engineer to prevent ingress of water

(k) at ladders and other openings, 12 mm minimum galvanised steel safety chains with
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eyebolt and harness type snap attachments shall be installed.
3 Stainless steel handrailing shall generally be as designated for galvanised steel handrailing
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except that all materials shall be of stainless steel Grade 316 S 31, including stainless steel
safety chains and attachments.
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4 Aluminium handrailing shall generally be as designated for galvanised steel handrailing

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except as modified below:

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(a) handrailing shall comprise double line handrails made from minimum 43 mm
outside diameter 9 SWG tube to BS 1474 Grades 6036-T6, 6082-T6 unless otherwise
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designated
(b) fixings shall be of stainless steel
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(c) at ladders and other openings, two stainless chains shall be installed which shall be
fixed to hand rail standards or ladder stringers using suitable aluminium alloy hooks.
5 All joints shall be made within standards and shall consist of a dowel to provide rigidity fixed
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within the handrailing using countersunk stainless steel grub screws. Where removable
lengths of handrails are detailed half lap joints shall be used.
6 Make provisions for handrails in the exterior and interior installations subject to high humidity
to drain water from railing system.
7 Posts mounted handrails in concrete, bends and elbows occurring at low points, drill weep
holes of 6 mm diameter at lowest possible elevations, one hole per post or rail. Drill hole in
the plane of the rail.
6.4.6 Chequer Plate

1 General
2
(a) all chequer plate shall be designed to support uniformly distributed loads of 7.5 kN/m .
The loading shall be considered a minimum requirement. Where an item of
equipment demands larger loading, the loading shall be increased accordingly.
(b) maximum deflection shall be 0.2 % of the span under maximum loading
conditions for steel flooring and one per cent for Aluminium
(c) plate sections shall
(i) have a minimum thickness of 6 mm, excluding the raised pattern
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(ii) Plates shall be reinforced with angle sections of the same material to meet the
above loading and deflection requirements.
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(iii) be of diamond shaped pattern at the top and have an angled and opposed
pattern which shall be non-slip type
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(d) joints shall be provided at the centre of all openings unless otherwise shown on the
Drawings
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(e) joints and openings shall be reinforced with additional stiffeners where necessary
to provide the required load carrying capacity and deflection criterion.
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2
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Galvanised steel chequer plate and frames shall be hot dip galvanised after fabrication, and
all fasteners shall be stainless steel. Where specified on the drawings galvanised chequer
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plate flooring shall in addition be epoxy coated.
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3 Aluminium chequer plate and frames shall be fabricated from aluminium alloy to BS EN 755-
9, Grade 6082-T6, and all fasteners shall be stainless steel A4. Gaskets shall be provided to
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isolate aluminium alloy from other materials.
4 Flooring shall be provided in sizes suitable for removal by one man and with the appropriate
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cutouts to permit its removal without disturbing or dismantling spindles, supporting brackets
or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which
shall be deemed to be included in the cost of the flooring.
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5 Chequer plate flooring covering openings in concrete or brickwork shall be set flush in frames
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of the same material fixed as shown on the drawings.

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6.4.7 Gratings and Open Mesh Flooring

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1 General
(a) all flooring and walkways shall be designed to support uniformly distributed loads of 7.5
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2
kN/m
(b) gratings and open mesh flooring shall be welded, rectangular opening type, bar
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gratings with seat angles, anchors and supports of the same material
(c) grating up to and including 1.0 m shall be furnished in pieces approximately 1.0 m in
width and all gratings for pans greater than 1 m shall be furnished in pieces 0.8 m in
width
(d) openings required in gratings shall be banded where openings are provided and shall
be strengthened as necessary
(e) installed units shall be true to plane and free of warps and irregularities
(f) units shall be divided for ease of installation and removal
(g) bearing bars shall be serrated and have a minimum size of 45 mm deep by 5 mm
thick
(h) the edges of all flooring and platforms shall be finished with approved kerbs, which
shall be provided by the flooring supplier and shall be fitted with fish tail lugs for
building into the concrete work
(i) the pattern, design thickness and finish shall be approved by the Engineer. The
pattern of open type flooring shall be rectangular and shall match between adjacent
panels
(j) flooring and walkway supports shall be independent of bearing supports to prevent the
setting up of oscillations and noisy vibrations
(k) all clips and bolts shall be stainless steel
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(l) all supporting metal work shall be provided on large area openings to provide
support for the flooring
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(m) the faces of flooring which come into contact with cement mortar concrete shall have
two coats of bituminous paint before installation of the frame.
2 Galvanised steel gratings and open mesh flooring shall be hot dipped galvanised after
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fabrication.
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3 Aluminium gratings and open mesh flooring shall be manufactured in approved structural
aluminium BS 1471, BS 1472 or BS 1474, Grade 6063-T6 or 6082-T6 unless otherwise
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designated and all fastens shall be stainless steel. Gaskets shall be provided to isolate
aluminium alloy from other materials. M
4 Stainless steel gratings and open mesh flooring shall be manufactured of Grade 316S31 to
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BS 970.
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5 Flooring shall be removable and set flush in frames of the same material. Frames shall be
fixed as shown on the drawings.
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6 The deflection under maximum load shall not exceed 0.2 per cent of the span for steel
flooring and one per cent for aluminium.
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7 Flooring shall be provided in sizes suitable for removal by one man and with the appropriate
cut-outs to permit its removal without disturbing or dismantling spindles, supporting brackets
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or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which
shall be deemed to be included in the cost of the flooring.
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8 Steel angle support frames to be embedded in concrete shall be stainless steel,

BS EN 10272:2000 Type 316, unless indicated otherwise.
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9 Welded anchors for stainless steel support frames shall also be stainless steel.
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END OF PART
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Part 07: Glass Reinforced Plastics
7 GLASS REINFORCED PLASTICS ................................................................ 2
7.1 GENERAL ...................................................................................................... 2

7.1.1 Scope 2
7.1.2 Related Sections and Parts 2
7.1.3 References 2
7.1.4 Submittals 2
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7.1.6 Warranty 3
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7.2 MATERIALS .................................................................................................. 3
7.2.1 GRP 3
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7.3 FABRICATION AND ERECTION ................................................................... 3
7.3.1 GRP Ladder 3
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7.3.2 GRP Handrails and Balustrades 4
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7.3.3 GRP Gratings and Open-Mesh Flooring 4
7.3.4 GRP Lining for Pump Station Wet Wells 4
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7 GLASS REINFORCED PLASTICS

7.1 GENERAL
7.1.1 Scope
1 This part includes the specifications for all work in connection with glass reinforced plastics
(GRP) ladders, safety cages, handrails, balustrades, gratings, open-mesh flooring, and
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linings for pump station wet wells.
7.1.2 Related Sections and Parts
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Section 1 - General
This Section
Part 1 General
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Part 3 Pipes and Fittings Materials
Part 4 Pipe Installation
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Part 6 Metal Works
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7.1.3 References M
1 The following standards are referred to in this Part:
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ASTM E84 ..................Test Method for Surface Burning Characteristics of Building Materials
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BS 3532......................Method for specifying unsaturated polyester resin systems

BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester
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and epoxy resin systems.
BS EN 14118..............Reinforcement. Specifications for textile glass mats

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7.1.4 Submittals
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1 Manufacturers’ Literature:
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(a) the Contractor shall provide manufacturers’ specifications, load tables, dimension
diagrams, anchor details and installation instructions for products to be used in
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GRP works.
2 Design Calculations and Shop Drawings:

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(a) the Contractor shall provide design calculations and shop drawings for the
fabrication and erection of all assemblies of GRP which are not completely shown in
manufacturers’ data sheets, including anchorage and accessory items
(b) plans and elevations in metric dimensions not less than 1:20 scale, and details of
sections and connections at not less than 1:10 scale shall be included. Detailed
drawings shall show material type, thickness grade/class dimensions, and construction
scheme
(c) the submittal shall include catalogue pages, erection description, manufacturers’ data
and instructions and templates where appropriate.
1 Fabricated GRP products and materials shall be provided by experienced approved

manufacturers and fabricators as designated in the contract specific documents and
manufactured to approved patterns.
7.1.6 Warranty
1 The Contractor shall provide the Employer with a 7-year unconditional guarantee against
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failure of all GRP products whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be handed to
the Engineer before the issue of the Certificate of Completion.
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7.2 MATERIALS
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7.2.1 GRP
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1 GRP material for ladders, safety cages, handrails, balustrades, grating and open-mesh
flooring shall be fabricated from structural quality fibreglass shapes with chemical and
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ultraviolet resistance. Resin shall be all vinyl ester. Glass shall be all ECR and GRP
thickness shall be a minimum 5 mm. The top surface shall be provided with a non-slip silica
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sand finish. The structural components shall have Class I fire retardance, with an ASTM E84
flame spread rating of 25 maximum. Fibreglass components shall have an ultimate tensile
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strength of 207 MPa, an ultimate compressive strength of 207 MPa, a modulus of elasticity of
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20.7 GPa, and a Barcol hardness of 50.

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2 All cut or trimmed edges of the GRP ladder and braces shall be flow coated with an approved
vinyl ester resin. Glass fibres shall not be exposed.
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7.3 FABRICATION AND ERECTION

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7.3.1 GRP Ladder

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1 GRP ladders shall be obtained from an approved experienced manufacturer and shall be
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purpose made to suit the depth of each installation as shown on the drawings. The ladders
shall be drilled for wall fixing at both ends and additional intermediate fixing connections shall
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be provided at centres not greater than 1.5 metres. Rungs shall be at 300mm centres and at
a distance of not less than 200mm from the wall. Rungs if tubular shall be no less than
30mm outer diameter, and stringers shall be of a rectangular or channel section no less than
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70mm x 25mm in size.
2 The wall thickness of the laminate shall be not less than 5 mm at any point and there shall be
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no sharp edges. The support fixing brackets shall be GRP continuously moulded with the
main lamination and they shall be not more than 500 mm apart (every 2 steps/rungs). The
rungs shall be 250 mm apart with the upper face finished with a non-slip surface.
3 The support fixing brackets shall be put through the liner wall, and be designed to be totally
encapsulated by concrete. The ladder brackets shall be laminated to the outside of the liner.
4 Each rung shall be able to withstand a point load of 5000 N.

5 When supported horizontally over a span of 1.0 m with the climbing face uppermost and with
a load of 1000 N applied at the centre of the span the ladder shall not deflect more than 15
mm at the point of application of the load and shall show no permanent deflection after
removal of the load. Each ladder fixing shall be capable of withstanding shear and pull-out
loads of 5000 N.
7.3.2 GRP Handrails and Balustrades
1 GRP handrails and balustrades shall be white (or near white) in colour and shall be obtained
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from an approved experienced manufacturer.
2 The resin, glass and synthetic fibres used in the manufacture of handrails shall be chosen to
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produce a chemically resistant product with a resin-rich surface layer suitable for use in
aggressive atmospheres likely to be encountered in sewers and sewage pumping stations.
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3 Standards shall be no smaller than 45 mm square, and shall be 1100 mm high. Base fixing
shall be as shown on the drawings. Where installed on concrete surfaces using expanding
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anchor bolts, the bases shall be bedded on an approved mastic sealant to prevent ingress of
water to the bolt holes.
4
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Handrails shall be no smaller than 50 mm square, and shall be located 550 and 1100 mm
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above finished floor level on standards spaced no more than 1500 mm apart. Deflection
under vertical loads shall be no greater than deflection under the same horizontal load.
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5 The complete installation shall be capable of withstanding a horizontal force at top rail level of
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740 N/m. The deflection of both rails and standards shall not exceed 2 % of the span/height
under a horizontal load of 360 N/m on the top rail.
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6 At ladders and other openings, two removable stainless steel chains, shall be installed which
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shall be fixed to handrail standards or ladder stringers using stainless steel (316 S31) hook
bolts.
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7.3.3 GRP Gratings and Open-Mesh Flooring

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1 GRP grating and open-mesh flooring shall have the same overall dimensions and design
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criteria as designated for steel grating and open-mesh flooring in Part 6 of this Section except
as modified below.
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2 The grating shall be of one piece compression moulded continuous fibreglass strand bar type
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grating and other requirements shall be as designated for GRP ladders. The colour and
pattern of the grating and open-mesh flooring will be selected from the available
manufacturer’s standards and to the approval of the Engineer.
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7.3.4 GRP Lining for Pump Station Wet Wells
1 GRP linings to pumping station shall consist of a chemically resistant layer comprising vinyl
ester resin suitably reinforced with a “C” glass or synthetic tissue veil. This layer shall be no
less than 6 mm thick, and shall have a resin content by weight of approximately 90 % at the
exposed surface, reducing to 65 % - 75 % at the inner surface. The remainder of the liner
shall consist of vinyl ester or isophthalic resins “ECR” glass chopped strand mat. The lining
shall be at least 6 mm thick and shall be white (or near white) in colour.
2 All linings shall consist of preformed sheets and tubes with moulded on lugs to allow bonding
to concrete. Joints between sheets shall be bandaged on the hidden face, with the
bandaging extending 150 mm either side of the joint. On the inside (exposed) face the joint
shall be filled with vinyl ester paste to produce a smooth finish. Where joints form angles, a
50 mm radius fillet shall be formed using vinyl ester paste prior to bandaging.
3 Where the Engineer permits the use of GRP lining to upper surfaces, and other areas where
casting in of preformed sheets in inappropriate, lapping of in-situ work onto preformed work,
and application of in-situ lining shall be carried out as follows:
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(a) at the junction between preformed linings and in-situ linings, the preformed lining shall
be lightly abraded to a distance of 150 mm from the junction
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(b) a vinylester paste fillet of 50 mm radius shall be formed at internal angles which are
to receive an in-situ lining
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(c) the in-situ lining shall be built up by applying isophthalic or vinyl ester resin to the
whole of the surface to be lined, the fillet and the abraded strip of the preformed lining
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(d) a layer of “E” or “ECR” mat shall be rolled into the resin using a suitable steel roller to
exclude all air and provide complete immersion of glass fibre in the resin
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(e) after a period to allow pre-gel to a tacky state a second coat of resin shall be applied
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followed by a further layer of glass fibre mat. This process shall be repeated until the
total thickness of the lining is approximately 4 mm
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(f) vinylester resin and “ECR” glass or synthetic tissue veil shall than be applied in layers
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to complete the lining

(g) where linings are applied to inverts of channels subject to high fluid velocities of 5 m/s,
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the GRP lining shall be mechanically fixed to the substrate using stainless steel screws
and washers. After building up approximately 60 % of the required thickness of lining,
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stainless steel round headed screws 50 mm long and stainless steel washers 25 mm
diameter shall be used at 500 mm centres (by drilling and plugging) to fix the lining to
the concrete. Particular attention shall be paid to edges of sheets where the flow of
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sewage will tend to lift the lining. The remaining layers of GRP shall then be built up
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over the screw heads and washers.

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4 The top surface of benchings and platforms shall incorporate silica sand to form a non-slip
surface.
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END OF PART
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Part 08: Painting and Protective Coatings
8 PAINTING AND PROTECTIVE COATINGS .................................................. 2
8.1 GENERAL ...................................................................................................... 2

8.1.1 Scope 2
8.1.2 References 2
8.1.3 Definitions 3
8.1.5 Submittals 4
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8.1.8 Warranty 5
8.1.9 Safety 6
8.2 MATERIALS .................................................................................................. 6
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8.2.1 Coating and Painting Materials 6
8.2.2 Coating and Painting Systems 7
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8.2.3 Abrasive Blasting Materials 13
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8.3 WORKMANSHIP ......................................................................................... 13
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8.3.1 General 13
8.3.2 Manufacturer’s Recommendations 14
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8.3.3 Mixing and Thinning 14
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8.3.4 Items Not to be Painted During Coating and Painting Operations 14

8.3.5 Surface Preparation 14
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8.3.6 Application of Protective Coatings and Paint 18

8.3.7 Maintenance of Prepared Surfaces 19
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8.3.8 Environmental Conditions 19

8.3.9 Spray Application 20
8.3.10 Brush Application 20
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8.3.11 Shop Coatings 20

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8.3.12 Site Painting of Manufactured Items 20

8.3.13 Site Application 21
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8.3.14 Epoxy Coating Work 21

8.3.15 Epoxy Coatings for Concrete and Rendered Surfaces 22
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8.3.16 Galvanising and Other Finishes of Metals 22

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8 PAINTING AND PROTECTIVE COATINGS

8.1 GENERAL
8.1.1 Scope
1 This part includes the specification for the Provision of protective coatings and painting to
protect the surfaces of structures, materials and equipment in interior, exterior, process,
operating, and maintenance service environments as classified in this Part.
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2 Related Parts and Sections are as follows:
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This Section
Part 1, General
Part 5, Valves, Penstocks and Appurtenances
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Part 6, Miscellaneous Metal Work
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Section 1, General
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Section 5, Concrete
Section 6, Road works M
Section 16, Structural Metalwork
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Section 17, Metalwork

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Section 21, Electrical Works

Section 26, Painting and Decorating.
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8.1.2 References
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1 The following standards and other documents are referred to in this Part:
ASTM C97 ..................Standard Test Methods for Absorption and Bulk Specific Gravity of
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Dimension Stone
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BS 245........................Mineral solvents (white spirit and related hydrocarbon solvents) for

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paints and other purposes

BS 1336......................Knotting
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BS 1710......................Identification of pipelines and services

BS 4232......................Surface finish of blast-cleaned steel for painting
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BS 4652......................Zinc-rich priming paint (organic media)

BS 4756......................Ready mixed aluminium priming paints for woodwork
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BS 4800......................Paint colours for building purposes

BS 5493......................Code of practice for protective coating of iron and steel structures
against corrosion
BS 6150......................Code of practice for painting of buildings
BS 7079......................Preparation of steel substrates before application of paints and related
products
BS 7956......................Specification for primers for woodwork
BS EN 10300..............Bitumen-based hot-applied coating material for protecting iron and

steel, including suitable primers where required
BS EN ISO 1461 ........Hot dipped galvanised coatings on iron and steel articles
SIS 055900.................Rust grades for steel surfaces and preparation grades prior to
protective
coating
8.1.3 Definitions
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1 Paints, protective coatings, and coatings: paints, enamels, stains, varnishes, lacquers,
sealers, fillers and other types of coatings whether used as primers, intermediate or finish
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coats.
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1 For purposes of identifying protective coating and painting systems to be applied as specified
in this Part, service environments are classified in Table 8.2.
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2 The classification of areas and surfaces to be coated or painted shall be as designated in the
Project Specification. M
3 Painting in unclassified areas shall be carried out as specified in Section 26.
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4 Surfaces to be Coated or Painted. In general, the following surfaces are to be coated or
painted:
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(a) all exposed piping and other metal surfaces, interior and exterior
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(b) all submerged metal surfaces

(c) all structural and miscellaneous steel work, including tanks
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(d) interior of tanks, chambers and wet wells that are not protected with GRP or PVC
liners
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(e) exterior above ground concrete as Table 8.5 unless otherwise designated in the
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Project Specification
(f) exterior above ground brick masonry as designated in the Project Specification
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(g) interior of structures as designated in the Project Specification.

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(h) equipment furnished with and without shop finished surfaces, except as specified in
Clause 8.1.8
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5 Surfaces Not to be Painted or Coated. The following surfaces in general shall not be coated
or painted unless otherwise designated:
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(a) plastic surfaces

(b) non-ferrous metal (Galvanised metal shall not be considered a non-ferrous metal)
(c) mechanical equipment with approved, designated shop finish
(d) electrical equipment with shop finishes designated in the contract specific
documentation
(e) piping to be galvanised as designated in the Project Specification
(f) chain link fencing.
6 In no case shall any concrete, wood, metal, or any other surface requiring protection be left
unpainted unless otherwise directed by the Engineer or designated in the Project
Specification.
8.1.5 Submittals
1 Manufacturer’s Data. The manufacturer’s specifications and application instructions for paint
materials and systems, including certifications, verification of specified thickness and other
data to show compliance with these specifications shall be submitted to the Engineer.
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2 Painting Programme. A detailed painting programme including method statements shall be
submitted for the Engineer’s approval. This programme shall be prepared on the basis of
service environments, surfaces, surface preparation, types of paint materials, types of
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primers and sealers, and number of coats. The brand name of the product of the
manufacturer for each use shall be listed.
3 Samples. When required by the Engineer, samples for colour and texture as hereinafter
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listed shall be submitted for the Engineer’s approval. The Contractor shall be responsible for
compliance with all other requirements.
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4 Letter of guarantee required under Clause 8.1.8 of this Part.
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8.1.6 Quality Assurance M
1 Protective painting shall be carried out only by approved prequalified subcontractors as
designated in the Project Specification. Protective coating shall be carried out by specialist
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subcontractor as designated in the Project Specification.

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2 Applicator Qualifications: The Contractor shall provide information demonstrating that

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applicators have successfully completed coating system applications similar in material and
extent to those included in the Works. Only applicators for which such information has been
provided shall be employed.
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3 Single-Source Responsibility: The Contractor shall provide primers and undercoat material
produce by the same manufacturer as the finish coats for each type of coating. Only thinners
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recommended by the manufacturer shall be used, and only within the manufacturer’s
recommended limits.
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Field Samples: Where required by the Engineer field samples shall be provided as follows:
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(a) Sample Boards. The Engineer’s colour chips on 300 mm by 300 mm hardboard shall
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be matched with colour, texture and sheen duplicated to simulate actual conditions.
Sample boards shall be resubmitted as necessary for selection by the Engineer.
(b) Sample Areas. Where required by the Engineer, partial areas shall be prepared and
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finished as directed by the Engineer, using selected 300 mm by 300 mm sample

boards as a guide for final approval of colour, texture and sheen. After approval, the
sample areas shall serve as the standard for workmanship, appearance and materials
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for similar areas throughout the project.
4 All epoxy coating work shall be carried out by a specialist firm or contractor approved by the
Engineer. The specialist firm shall be required to submit a letter of guarantee that the
product it proposes to supply when applied in accordance with this specification and any
additional specifications which shall be quoted by the firm will withstand the environmental
service conditions to be encountered. The Contractor shall provide a guarantee of at least
three years in relation to this coating from the time of application of the coating.
1 Except as otherwise specified in this Part, delivery storage and handling of coating and paint
material shall be carried out as specified for paint material in Section 26.
2 Coating and painting materials and apparatus shall be stored in areas approved by the
Engineer. When not in use, storage areas shall be kept locked and inaccessible to those not
employed in protective coatings and painting work. Each storage space shall be provided
with fire extinguishers.
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3 Coating and paint containers shall be opened only when required for use. Unless otherwise
specified in this Part, no materials shall be reduced, changed, or used except in accordance
with the manufacturer’s label or tag on container.
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4 All coating materials and thinners shall be furnished by the Contractor in original, unopened
containers bearing the manufacturers label and instructions. For materials having a limited
shelf life, the date of manufacture and the length of life shall be shown. The oldest paint of
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each kind shall be used first.
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5 All coating materials shall be stirred in a container with a power mixer before use to
thoroughly remix the pigments and vehicles. Only thinners specified by the manufacturer
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shall be used. Mixing and thinning directions as furnished by the manufacturer shall be
followed unless modified by the Engineer’s Representative.
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6 Mixing in open containers shall be done in a well ventilated area. When use of thinner is
permitted, thinner shall be added during the mixing process.
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7 If a coating material requires the addition of a curing agent, the pot life under application
conditions stated on the container label shall not be exceeded. When the pot life limit is
reached, the spray equipment shall be emptied, remaining material discarded, the equipment
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cleaned and the new material prepared.

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8 For paints and thinners, records shall be kept of:
(a) Date of manufacture.

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(b) Shelf life.

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(c) Date of use.

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(d) Daily usage of thinners.
9 Preparation of the paint for application shall be as BS 5493 and the Manufacturers
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recommendations.
10 Coating materials, other than thixotropic materials, which have livered, gelled or otherwise
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deteriorated shall not be used.
11 No paint shall be used on expiry of the manufactures recommended shelf life nor when the
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paint solids cannot be dispersed by mixing after a maximum of 5% thinners has been added.
8.1.8 Warranty
1 Before beginning coating and specialist paint work, the Contractor shall provide the Engineer
with a letter of guarantee from the specialist subcontractor that the products proposed for use
when applied in accordance with the specifications of this Part and the manufacturer’s
instructions will withstand the environmental service conditions to be encountered for a
period of 10 years.
8.1.9 Safety
1 The implementation of manufacturer’s recommendations concerning health and safety

aspects of paints approved by the Engineer for use on the works shall be mandatory.
2 Respirators shall be worn by all persons engaged in, and assisting in, spray painting. In
addition, workers engaged in or near the work during sandblasting shall wear eye and face
protection devices meeting the Engineer’s approval for sandblasting operations and
approved air-purifying, half-mask or mouthpiece respirator with appropriate filter.
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3 Where ventilation is used to control potential exposure to workers, ventilation shall be
adequate to reduce the concentration of the air contaminant to such safe limits that a hazard
to the worker does not exist. Methods of ventilation shall meet with the approval of the
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Engineer.
4 Cloths and cotton waste that may constitute a fire hazard shall be placed in closed metal
containers or destroyed at the end of each work day.
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8.2 MATERIALS
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8.2.1 Coating and Painting Materials
1
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Epoxy coating and painting materials shall be as follows:
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(a) Primer
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(i) solvent-free low viscosity
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(ii) (ii two or three pack

(iii) compatible with and have complete intercoat adhesion with the first coat of high
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build epoxy paint

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(b) Protective coats

(i) high build straight aromatic amine cured epoxy
(ii) two or three pack
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(iii) solvent free type

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(iv) completely resistant to the corrosion conditions to be encountered.

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Certain types of coal tar epoxy may also be approved by the Engineer for this purpose
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in which case the Contractor shall state the type of coal tar and the curing agent to be
used and the percentage content of coal tar.
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2 Stone Paint. Stone paint to be used on exposed external concrete surfaces shall be single
component silane siloxane based water repellent system with not more than 1% water
absorption when tested in accordance with ASTM C97.
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3 Fungus and Mould Resistant Finishes. Where a fungus and mould resistant surface is
designated, the surface shall be treated with a fungicide paint in accordance with the
manufacturer’s instructions.
4 Varnish: Varnish shall comply with the relevant provisions of BS EN ISO 150.
5 Where a surface is to receive more than one type of coating or painting material, each
different material used on that particular surface shall have a different colour in order to
facilitate inspection. Colour schedules for coating and painting materials shall be prepared by
the Contractor and submitted to the Engineer for approval.
6 The list of manufacturers of all paints/coatings/corrosion control systems shall be submitted

for approval by the Engineer.
7 All materials for lining/multiple coat work, e.g., priming, undercoat and finishing coat shall be
obtained from the same manufacturer and shall be suitable for using together and for the
surface concerned.
8 All materials shall be used strictly in accordance with manufacturer’s instructions.
9 Manufacturer's samples of all paints, varnishes, etc., shall be submitted, free of cost, in
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sealed containers to the Engineer for approval before bulk deliveries are made and before
any paintwork is started.
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8.2.2 Coating and Painting Systems
1 The materials, application and use of coating and painting systems are specified in
Tables 8.1 to 8.5. Surfaces in Location A shall receive a total paint thickness of not less than
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200 micron and the surfaces in Location B, C and D shall receive a total paint thickness of
not less than 300 micron. The first coat of paint to be applied not more than 4 hours after
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substrate preparation. Subsequent coats of paint to be applied within 48 hours of previous
coat. Approval to factory application of this final coat to be sought from the Engineer where
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delay in application is liable to cause adhesion problems.
2
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Formulate paints with colorants free of lead, lead compounds, or other materials that might
be affected by presence of hydrogen sulfide or other gas likely to be present at Site.
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3 Identification of pipelines shall be generally in accordance with the Contract Drawings or

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Specification or as selected by the Engineer.
4 Pipelines shall be identified by the colours in Table 8.6. These shall be applied as follows:
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(a) Painting the basic identification colour on the pipe or duct over the whole length and
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super-imposing the colour code identifications at intervals; or

(b) Painting the pipe or duct in bands.
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5 Where banding is adopted, the decorative or protective colour along the rest of the pipe or
duct shall not be any of the basic identification colours.
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C
6 The basic identification colours shall be placed at all junctions at both sides of valves, service
appliances, bulkheads, wall penetrations and any other place where identification is
necessary.
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7 Any information regarding the fluid such as pressure, temperature, etc., shall be placed on
the basic identification colour or next to the basic identification colour band. The names,
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abbreviations or chemicals symbols shall be either in black or white in order to contrast

clearly with the colour of the pipe or with the basic identification colour. The direction of flow
of the fluid shall be indicated by an arrow situated in the proximity of the basic identification
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colour and painted black or white in order to contrast clearly with basic identification colour.
8 For closed circuits, the flow and return pipes shall be indicated by the use of the word "Flow"
on the one pipe and the word "Return" on the other.
Table 8.1
Schedule of Paints and Film Thickness per Coat (DFT)
DFT
Ref. Description
microns
Zinc phosphate epoxy corrosion resistant primer
P1 50
Two pack polyamide cured.
P2 Zinc Chromate ditto 50
P3 Zinc phosphate epoxy prefabrication primer. Two pack 50
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P4 Zinc chromate ditto 50
T-wash pretreatment for galvanised
T 50
surfaces as described in BS 5493
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Epoxy micaceous iron oxide. Two pack.
U1 125
Polyamide cured.
U2 Pure epoxy resin. Two pack. Amine adduct cured. 125
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U3 Coal tar epoxy. Two pack. Polyamide cured 125
U4 Epoxy tie coat -
D
F1 Silicone alkyd enamel 25
ID
F2 Urethane. Two pack. -
X Hot dip bitumen solution to BS 4147, Type 1 Grade D* -
M
Y Aluminium sealer. Single pack -
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Table 8.2
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Key to Preparation and Painting Schedule

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Item Locations
Surfaces above process liquid level and not liable to splashing. Non-aggressive
A
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atmospheres.
B Surfaces in contact with untreated or treated water for potable use.
Surfaces below process liquid level or liable to splashing. Non aggressive
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C
solutions and/or atmospheres.
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D Surfaces in contact with aggressive solutions and/or atmospheres.

C
Table 8.3
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Preparation Standards for substrates
Item Preparation Standards for substrates

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GB Grit blast to Swedish Standards Sa 2 1/2

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Z Clean and degrease

Pickle and hot dip galvanise to BS 729 (applied to items which may be pieced
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sufficiently small and excludes stainless steel).
Table 8.4
Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes)
Item Item Item Factory Operations
Location Assembly Prep. Coatings
Completed at 1st 2nd
Steel and Ferrous metal parts A Factory GB P1 (a) or P2 (a) U1 (b)
or G - -
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Site GB P3 (a) or P4 (a) -
B Factory GB P1 (a) U2 (b)
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or G - -
Site GB P3 (a) -
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C Factory GB P1 (a) or P2 (a) U3 (b)
or G - -
D
Site GB P3 (a) or P4 (a) -
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D G T and P1 -
Cast iron and cast steel A GB P1 (a) or P2 (a) U1 (b)
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including headstocks B GB P1 (a) U2 (b)
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C GB P1 (a) or P2 (a) U3 (b)
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Non-ferrous metal (except A Z P1 (a) or P2 (a) U1 (b)

copper) B Z P1 (a) U2 (b)
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C Z P1 (a) or P2 (a) U3 (b)

Steel pipes A/B/C/D G - -
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Iron and steel A/C/D Z - X

B GB P1 (a) U2 (b)
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Penstocks and valves of A/C/D Z - X

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cast iron B GB P1 (a) U2 (b)

C
Steel stairways and

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supporting
Structures A/B/C/D G - -
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Bridge rail and pin rack rail

Water Towers (Exterior) D Site GB P1 (a) U1 (b)
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Table 8.4 (Cont’d)

Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes)
Item Site Operations and Coatings
Item
Item Assembly
Location 1st 2nd 3rd 4th
Completed at
Steel and Ferrous metal parts A Factory F1 F1 - -
- - - -
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Site P1 (f) or P2 (f) U1 (b) F1 F1
B Factory U2 (c) - - -
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- - - -
Site P1 (f) U2 (b) U2 (b) -
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C Factory U3 (c) - - -
- - - -
D
Site P1 (f) or P2 (f) U3 U3 (b) -
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D P1 (f) U3 U3 (b) -
Cast iron and cast steel A F1 F1 - -
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including Headstocks B U2 (c) - - -
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C U3 (c) - - -
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Non-ferrous metal (except A F1 F1 - -

copper) B U2 (c) - - -
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C U3 (c) - - -
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Steel pipes A/B/C/D - - - -

Iron and steel A/C/D Y Y F1 F1
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B U2 (b) - - -
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Penstocks and valves of A/C/D X - - -

cast iron B U2 (c) - - -
C
Steel stairways and supporting

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Structures A/B/C/D - - - -
Bridge rail and pin rack rail
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Water Towers (Exterior) D Site U4 F2 - -

Qualifying Notes:
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(a) To be applied not more than 4 hours after substrate preparation.

(b) To be applied within 48 hours of previous coat.
(c) Approval to factory application of this final coat to be sought from the Engineer’s
Representative where delay in application is liable to cause adhesion problems.
(d) Refer to Clause 8.3.5.35
Table 8.5
Preparation and Painting Schedules for Surfaces Other Than Metal
Surface Location Finish Particular Primer Final Treatment
Preparation
Hard Wood and Interior Gloss Sand down Q.D. Acrylic Alkyd undercoat
Soft Wood Treat Knots Wood primer Alkyd topcoat
(primed or
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unprimed) Exterior Gloss Sand down Lead free Alkyd undercoat
Treat Knots Wood primer Alkyd topcoat (2 coats)
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Plaster Interior Flat Degrease Emulsion thinned to High opacity acrylic
(including Sand down manufacturer's emulsion (2 coats)
Plasterboard) instructions
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Interior Gloss Ditto Alkali resistant Alkyd undercoat
D
primer Alkyd topcoat
ID
Interior Multi- Ditto Primer Multi-colour wall finish
colour M
Cement Interior Flat - Emulsion thinned to High opacity acrylic
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Rendering, manufacturer's emulsion (2 coats)
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Concrete - instructions
(fair-faced), Interior Gloss - Alkali resistant Alkyd undercoat
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Brickwork primer Alkyd topcoat

Immersed & splash (Refer to the clause entitled Epoxy Coatings for Concrete and
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zone Rendered Surfaces)

Aggressive
N
atmospheres
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Exterior Masonry Stiff brush Stabilising primer Textured emulsion

masonry
C
paint paint (2 coats)

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Hardboard Interior Flat Zinc chromate High opacity acrylic High opacity acrylic
spot primer to emulsion emulsion (2 coats)
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screw and nail

heads
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Interior Gloss Ditto Stabilising primer Alkyd undercoat

Alkyd topcoat
Table 8.6
Standard Colours
The following colours to BS 4800 shall be used for mechanical and electrical equipment. For
equipment not listed the colour shall be agreed with the Engineer.
Material / Equipment Properties Colour
(a) External machinery 18 E 53 Green-Yellow
(b) Motors and Pumps 14 E 53 Green – Yellow
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(c) Panels 14 E 53 Green – Yellow
(d) GRP Covers 08 B 15 Yellow-Red
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(e) Sewage Pipework 00 E 53 Black
(f) Airlines 20 E 51 Light Blue
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(g) Sewage valves 00 E 53 Black
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(h) Airline Valves 20 E 51 Light Blue
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(j) Water Pipework 12 M D 45 Green
(k) Water Valves 12 D 45 Green

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(l) Potable Water/Pipes/Valves 12 D 45 Green/18 E 53
Auxiliary Blue
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(colour code)
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(m) Surge Vessels 08 E 51 Yellow

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(n) Fire Extinguishing Systems 04 E 53 Red
(o) Bulk Storage Tanks Aluminium

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(p) Electrical Services 06 E 51 Yellow-Red

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(q) Cranes 08 E 53 Yellow

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(r) Control Panels, relay 14 E 53 Green-Yellow

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panels, Instrumentation
enclosures, fuse switches,
distribution boards,
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marshalling cubicles etc.

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8.2.3 Abrasive Blasting Materials
1 The abrasive employed in blasting shall be grades steel grit, ball shot, silica safe sand or
similar and shall be such that it will provide a surface roughness complying with the one
specified by the manufacturer for the primer concerned. The abrasive shall be dry, clean and
free from soluble contaminants and shall be selected as specified in BS 4232.
2 The type and size of abrasive used for blast cleaning shall comply with the requirements of
BS 4323 Table 2. When directed by the Engineer, the Contractor shall carry out a series of
tests using various sizes of abrasives smaller than the maximum defined in BS 4232 Table 2
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to determine which gives the best profile. This size of abrasive shall be used for all
subsequent blast cleaning. The grading of abrasives for equipment which uses abrasives
more than once shall be checked at regular intervals and fresh abrasives added to ensure
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that the correct grading is maintained.
3 The roughness of blast cleaned surfaces measured at the amplitude by any of the methods
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defined in BS 4232 shall not exceed 75 microns.
4 The pH value shall not be less than 4 or greater than 10 when mixed in neutral water. The
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material shall not contain soluble chloride.
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5 The level of trace toxic contaminants shall meet Government regulations.
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6 Dune sand shall not be used.
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8.3 WORKMANSHIP
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8.3.1 General
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1 Unless otherwise specified in this Part, the preparation coating and painting of surfaces shall
be carried out as specified in Part 26 and in accordance with the recommendations of
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BS 6150 subject to the approval of the Engineer.
2 All coatings and paint shall be applied in a workmanlike manner to produce a uniform film of
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the specified thickness. Edges, corners, crevices, and joints shall receive special attention to
ensure that they have been thoroughly cleaned and that they receive an adequate thickness
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of paint. The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush
marks, and variations in colour, texture, and finish.
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3 Before beginning coating and painting work, the Contractor shall take precautions to protect
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the Works and existing facilities from damage or disfigurement. Where necessary, the
Contractor shall protect equipment by providing clean cover sheets. If in the opinion of the
Engineer the precautions are inadequate, the Contractor shall at his own expense make such
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improvements as the Engineer directs.
4 The specified film thickness shall be attained. Particular attention shall be paid to the
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attainment of specified film thickness on edges. In hot weather, additional precautions shall
be taken as necessary to ensure the attainment of specified film thickness. Film thickness
shall be checked with a paint inspection gauge furnished by the Contractor. The Contractor
shall calibrate the gauge for the thickness range to be checked at least twice a day. When
measured film thickness is less than specified, additional coats shall be applied as necessary
to attain compliance.
5 Manual grit blasting equipment shall be approved by the Engineer before use. Air
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compressors shall be capable of supplying a continuous air volume of at least 6 m /min at a
maximum pressure of 7 MPa to each blasting nozzle. The compressed air supply shall be
free of water and oil. Adequate separators and traps shall be provided. Accumulations of oil
and water shall be removed from air receivers by regular purging.
6 On completion of the works, which may have become spotted or touched with paint shall be
cleaned down and all left clean to the satisfaction of the Engineer.
8.3.2 Manufacturer’s Recommendations
1 Unless otherwise specified, the coating and paint manufacturer’s written recommendations
and instructions for storage, thinning, mixing, handling, surface preparation, protection of
other surfaces, application and protection of coated and painted surfaces and for all other
procedures for providing protective coatings and painting shall be strictly observed. No
substitution or other deviation will be permitted without the written permission of the Engineer.
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8.3.3 Mixing and Thinning
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1 Coating materials and paint shall be mixed only in designated rooms or spaces in the
presence of the Engineer.
2 Paint and coating materials shall be protected from exposure to extreme weather, and shall
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be thoroughly stirred or agitated, strained, and kept at a uniform smooth consistency during
application. Materials shall be prepared and handled in a manner to prevent deterioration and
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inclusion of foreign matter.
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3 Paint and coating materials of different manufacturers shall not be mixed together.
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Packaged paint and coating materials may be thinned immediately before application in
accordance with the manufacturer’s directions. Only thinners recommended by the paint and
coating manufacturer shall be used.
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8.3.4 Items Not to be Painted During Coating and Painting Operations

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1 Hardware, hardware accessories, name plates, data tags, machined surfaces and similar
items in contact with coated surfaces shall not be coated and shall be removed or masked
before surface preparation and painting operations. Following completion of coating of each
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piece, removed items shall be reinstalled. Such removal and reinstallation shall be done by
workmen skilled in the trades involved.
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2 That portion of steel to be embedded in concrete or masonry shall not be painted and shall
be cleaned as designated for steel surfaces before fixing.
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8.3.5 Surface Preparation

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1 General
(a) The specified standard of surface preparation shall be attained. Surface preparation
shall have no detrimental effect on the material being protected and shall not be
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prejudicial to subsequent coating and painting operations.

(b) In addition to complying with the specifications of this Clause and the manufacturer’s
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instructions the Contractor shall take such other measures needed to ensure that all
surfaces are clean, and free of deleterious material including but not limited to dirt,
grease, and oil, before the application of primer and between coats.
(c) All surfaces prepared for coating and painting shall be prepared to the specified
standard and approved by the Engineer before coating and painting work begins.
(d) Cleaning and painting shall be so arranged that dust or spray from the cleaning
process will not fall on wet, newly painted surfaces. The sharp edges of steel surfaces
shall be dulled, rough welds made smooth and weld splatter removed. Hardware,
electrical fixtures and similar accessories shall be removed or suitably masked during
preparation and painting, or shall be suitably protected. Equipment adjacent to walls
shall be disconnected and moved to permit cleaning and painting of wall surfaces, and
shall be replaced and reconnected after the painting has been completed.
Notwithstanding anything in this Section, all surfaces shall be prepared in strict
accordance with the approved paint manufacturer's recommendations.
(e) Do not apply paint in temperatures or moisture conditions outside of manufacturer’s
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recommended maximum or minimum allowable.
(f) Overcoating intervals recommended by the paint manufacturer must be strictly
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adhered to. The manufacturer must be consulted if and when there is a necessity for a
change in overcoating intervals.
(g) Where a high quality finish is required, the surfaces shall be filled with an approved
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filler 24 hours after the final priming coat has been applied. When the surface is hard
the whole shall be rubbed down with wet and dry abrasive paper to a uniform flat
surface and left clean and free of abrasions and powdered filler.
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(h) All surfaces are to be completely dry and above a temperature of 4 degrees C. No
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painting shall be carried out during damp or inclement weather.
(i) When required by equipment specifications, such equipment shall be primed and finish
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coated in shop by manufacturer and touched up in field with identical material after
installation.
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(j) Where manufacturer’s standard coating is not suitable for intended service condition,
Engineer may approve use of a tie-coat to be used between manufacturer’s standard
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coating and specified field finish. In such cases, tie-coat shall be surface tolerant
epoxy as recommended by manufacturer of specified field finish coat. Coordinate
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details of equipment manufacturer’s standard coating with field coating manufacturer.
2 Metal
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(a) Except as otherwise specified in this Clause, preparation of metal surfaces shall be in
accordance with the relevant provisions of BS 4232, BS 5493, BS 7079, and
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SIS 055900.
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(b) Steel to be embedded in concrete, other than reinforcing steel, shall be cleaned to SIS
055900 St. 2 and shall not be primed.
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(c) Surfaces shall be clean and dry before application of coatings and paint. If coating or
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painting takes place over a zinc rich shop primer which has been exposed for an
extended period, the entire coated surface shall be sweep blasted to remove “white
rust” and other contaminants before application of the first coat.
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(d) After the surface has been prepared as specified, the surface shall be further cleaned
by vacuum, clean and dry compressed air, or by clean brush to remove accumulated
grit, shot and dust leaving the surface clean, dry and free of scale, rust and other forms
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of contamination.
(e) In the event that rusting occurs after the completion of the surface preparation, the
surface shall again be prepared to the specified standard.
(f) When items are to be shop primed or shop primed and finish coated in the shop,
surface preparation shall be as specified herein. The Engineer shall have the right to
witness, inspect, and reject any sandblasting or other surface preparation done in the
shop.
(g) Blast Cleaning. Blast cleaning shall not be carried out
(i) on surfaces that are wet or damp surfaces, or may become wet or damp before
the application of primer,
(ii) when metal surface temperatures are less than 3 C above the dew point
(iii) or the relative humidity exceeds 80 percent.
(iv) In close proximity to subsequent coating operations or near other surfaces
susceptible to dust or particle contamination.
(h) In the event of shot or grit blasting not being possible due to interference, the steel
surface may, with the prior written approval of the Engineer, be thoroughly cleaned by
mechanical means in accordance with BS EN ISO 8504-3 to remove all loose rust and
mill scales and primed with one coat of an alkyd type zinc phosphate primer to
60 microns dry film thickness.
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(i) Where blast cleaning is to be carried out outdoors at an exposed (not under cover)
location, preliminary blast cleaning may be done at night with the prior approval of the
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Engineer, provided that all surfaces so treated shall be reblasted during daylight hours
to the specified standard before coating or painting materials are applied. This
paragraph does not apply where automatic centrifugal or manual grit blasting is carried
out under adequate cover, provided the specified preparation standard is attained.
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(j) Oil or grease contamination shall be removed by solvent wash before blast cleaning. If
necessary, contaminated areas shall be rewashed and reblasted until contamination is
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removed.
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(k) When sandblasting is carried out on Site, care shall be taken to prevent damage to
structures and equipment. Pumps, motors, and other equipment shall be shielded,
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covered, or otherwise protected to prevent the entrance of sand and dust. No
sandblasting shall commence before the Engineer inspects and approves the
protective measures.
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(l) After sandblasting, dust and spent sand shall be removed from the surfaces by
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brushing or vacuum cleaning.

(m) Blast cleaned surfaces that are later to be joined by welding and where shop primer is
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to be applied shall not be primed to a distance of 100 mm from the area to be welded.
After welding, the area shall be reblasted and primed as specified.
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(n) Areas that are blast cleaned and shop primed before fabrication and are later welded
on Site shall be reblasted to remove all weld slag and splatter and any other foreign
elements and reprimed as specified.
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(o) Fabricated metal work shall not be blast cleaned in the shop until machining and
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fabrication has been completed, including continuous welds, with all exposed surfaces
accessible for subsequent treatment. All slag and spatter shall be removed from the
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area of the welds by chipping hammer before blast cleaning.

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3 Concrete and Rendered Surfaces for Epoxy Coatings
(a) Concrete and rendered surfaces shall be thoroughly cured, thoroughly dry and free
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from moisture before the application of epoxy filler, primer or paint.

(b) Areas of concrete contaminated with substances deleterious to the application of
epoxy coatings including machine oil or grease for example shall be cut out as
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necessary to remove all traces of such substances. The voids so created shall be
filled with an approved epoxy mortar. Areas contaminated with form release agent
shall be scrubbed with suitable emulsion cleaners. Mould growth shall be treated
using a water soluble fungicide. All surfaces so treated and any other water soluble
substances on the surface, such as salt, shall be rinsed with potable water until clean.
(c) Where membranes have been used for the curing of concrete these must be removed
and the surfaces thoroughly cleaned before the application of painting and protective
coatings.
(d) All concrete and rendered surfaces to be coated shall be lightly blast cleaned to
remove the cement rich surface layer. Grit and detritus shall be removed by vacuum
immediately prior to priming.
(e) Blow holes and honeycombed areas in the concrete which in the opinion of the
Engineer are not capable of being levelled at the primer stage shall be filled with epoxy
mortar supplied by the coating manufacturer to obtain a smooth uniform surface. Such
mortar shall be knifed into the surface to level the area and leave no excess.
4 Preparation of Plaster, Brickwork and Concrete Surfaces for Coatings and Paint other than
Epoxy
(a) Efflorescence present on the surface of plaster, brickwork and concrete shall be
removed by scraping and brushing before any paint is applied. When efflorescence
has been removed surfaces shall be left for at least three days before priming.
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Priming shall be deferred repeatedly, if necessary, until three days after any further
efflorescence which has appeared is removed.
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(b) Plaster surfaces to be painted shall be cleaned down smooth as necessary and all
cracks filled in with stopping for plaster. Filling shall be carried out for the entire
surface before paint is applied to the surface.
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(c) Brickwork, blockwork and concrete surfaces shall be cleaned of contaminating matter
before being primed. Subject to the approval of the Engineer, large holes which would
cause a break in the paint film shall be filled with mortar and the surface rubbed down
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to match the surrounding areas.
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5 Wood
(a)
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Wood surfaces shall not be painted when the moisture content of the wood measured
with an electric moisture meter exceeds 12 % for interior surfaces and 18 % for
exterior surfaces.
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(b) Hardwoods or softwoods shall be rubbed down with abrasive paper to give a smooth
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surface free of contaminating substances, scratches and other imperfections.

(c) Surfaces which are to be painted shall be rubbed down to remove all contaminating
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substances and imperfections which would be visible in the finished paint film. The
surfaces of knots and resinous streaks shall be painted with two coats of knotting, the
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first being allowed to dry before the second is applied. Knotting shall conform with
BS 1336.
(d) The surfaces of timber treated with waterborne preservative by an impregnation
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process shall be rubbed down and dry-brushed to remove all traces of efflorescence
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before the primer is applied.

(e) Where surfaces are suspected of being infected with mould, they shall be treated with
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a fungicide.
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6 Galvanised Surfaces
(a) Dirt and other adhering contaminating material shall be removed by wire brushing,
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brushing with bristle brushes, or by other methods approved by the Engineer. Cleaning
shall not damage the galvanising. Zinc corrosion products remaining shall be removed
by washing with potable water and scrubbing with hard bristle brushes.
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(b) After being cleaned and degreased, galvanised surfaces shall be etched with T-wash
as described in BS 5493. If any surface fails to turn black, the cleaning, degreasing,
etching, and T-wash processes shall be repeated as often as necessary.
7 Damaged Surfaces
(a) Factory prepared surfaces, other than galvanised surfaces, during handling, site
fabrication or erection shall be treated as follows:
(i) all slag and spatter shall be removed from areas of welds by chipping hammer
(ii) all areas of damaged primer or other coat shall be thoroughly mechanically wire
brushed and given one priming coat as detailed in Table 8.3
(iii) the priming coat shall be applied by brush taking care to completely cover
uneven
surfaces particularly those of welds
(iv) subsequent coats shall be applied as specified in this Part.
8.3.6 Application of Protective Coatings and Paint
1 All paint and coating materials shall be applied in accordance with the manufacturer’s printed
specifications or instructions; where these differ from the specification of this Part, the more
stringent requirements shall apply. The Contractor shall issue copies of appropriate data
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sheets and of the relevant parts of this specification shall be issued to all supervisory
personnel. Where such instructions conflict with this specification a ruling shall be sought
from the Engineer’s Representative.
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2 Unless in conflict with the manufacturer’s printed instructions or otherwise specified, the
Contractor may use brush, roller or air spray. Application by spray painting shall be with the
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prior approval of the Engineer. Rollers for applying enamel shall have a short nap. Areas
inaccessible to spray coating or rolling shall be coated by brushing or other suitable means.
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3 The Contractor shall ensure that edges, corners, crevices, welds, bolts, and other areas, as
determined by the Engineer, receive a film thickness equivalent to that of adjacent coated
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surfaces and not less than the specified thickness.
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On beams and irregular surfaces, edges shall be stripe coated first and an extra pass made
later.
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5 Application of paint and condition of work shall be in accordance with manufacturer's

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recommendations and with BS 6150 and BS EN ISO 12944.

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6 The designated dry film thickness (DFT) shall be attained for each coat.
7 Each coat shall be applied evenly, at the proper consistency, and be free of brush marks,
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sags, runs, and other evidence of poor workmanship. When these occur, they shall be
brushed out immediately or the materials shall be removed and the surface recoated.
Finished coated surfaces shall be free from defects or blemishes.
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8 Care shall be exercised to avoid lapping paint on glass or hardware. Coatings shall be
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sharply cut to lines. Whenever two coats of a dark coloured paint are designated, the first
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coat shall contain sufficient powdered aluminium to act as an indicator of proper coverage, or
the two coatings shall be of a contrasting colour.
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9 All coatings shall be cleaned as specified by the manufacturer before the next coat is applied.
Manufacturer’s recommended time between coats shall be strictly complied with. Sufficient
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time shall be allowed to elapse between successive coats to permit satisfactory application of
subsequent coats. Once begun, the entire coating operation shall be completed without
delay. Without specific permission of the Engineer, no additional coating of any structure,
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equipment, or other item designated to be painted shall be undertaken until the previous
coating has been completed for the entire item. Piping shall not be finish coated until it has
been pressure tested and approved. Exposure of intermediate coats of paint for periods in
excess of a few days shall not be permitted except in the case of work delivered to the Site in
a primed condition and suitably protected.
11 Final coats shall not be applied until after other trades whose operations would be detrimental
to finish painting have finished their work in the area to be painted, and the areas have been
released for final painting.
12 All parts such as pipe supports, seatings and cleats, and back-to-back sections which will
become inaccessible after fabrication shall be treated on both surfaces with the full paint
system before final assembly.
13 Touch-up of all surfaces shall be performed after installation, and all surfaces shall be clean
and dry at the time of application.
14 All paints shall be prepared and applied in strict accordance with the manufacture
instructions. Copies of appropriate data sheets and of the relevant parts of this specification
shall be issued to all the supervisors and foremen concerned with surface preparation and
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coating. Where such instructions conflict with this specification a ruling shall be sought from
the Engineer’s Representative.
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15 Except where otherwise specified or approved by the Engineer’s Representative all priming
paints shall be applied by brush. Airless spray application only shall be used for painting pipe
lining and is the preferred method for the application of epoxy resin based paint.
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16 The dried films shall be free from bloom, shrinkage, sheeriness, wrinkling, sagging,
curtaining, discolouration and extraneous matter.
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17 Any primer coat exposed to freezing, excess humidity, rain, dust etc. before drying, shall be
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permitted to dry and the damaged area of primer shall be removed and surface again
prepared and primed. M
18 Bolted site connections other than facing surfaces of Grip Bolts shall be brought together wet.
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8.3.7 Maintenance of Prepared Surfaces

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1 Primer or other initial coat shall be applied to all prepared surfaces before deterioration or
oxidation of the surface. In the case of metals, primer or other initial coat shall be applied
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within one hour or such shorter period of time which may be recommended by the
manufacturer, but always before the metal temperature drops to less than 3 C above the
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dewpoint and before any rusting occurs. Unless otherwise approved by the Engineer for
surfaces other than metal, primer or other initial coat shall be applied within 4h of completion
of surface preparation. No prepared surfaces shall be allowed to remain uncoated overnight.
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8.3.8 Environmental Conditions

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1 Coatings and paint shall be applied in a dry and dust-free environment. Coatings and paint
shall not be applied to wet or damp surfaces or when, in the opinion of the Engineer,
application or drying of paint is likely to be adversely affected.
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2 No exterior or exposed paint work shall be carried out under adverse weather conditions; i.e.,
during rain, mist, windstorms, sandstorms, or when the relative humidity exceeds 80 %. Paint
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and coatings shall not be applied when it is expected that the relative humidity will exceed
80 % within 18 hours after the application of the coating or paint. Dew or moisture
condensation should be anticipated and if such conditions are prevalent, application of paint
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and coatings shall be delayed to be certain that the surfaces are dry. The paint or coating
shall be completed well in advance of the probable time of day when condensation is
expected to occur.
3 During application, painting shall insofar as practicable be shaded from direct sunlight to
prevent wrinkling and blistering. Exterior painting shall be carried out in shade during the
day.
8.3.9 Spray Application
1 All equipment for spray application shall be inspected and approved by the Engineer before
application begins. Spray guns hoses and pumps shall be clean before new material is
added. Adequate moisture and oil traps shall be installed between the air supply and each
application unit.
2 Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturer’s
recommendations.
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3 Heavy pigments which are likely to settle shall be kept in suspension during application by the
use of power driven, continuous agitator.
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4 The spray gun shall be held at right angles to the surface. Each pass shall overlap the
previous one by approximately 50 %.
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8.3.10 Brush Application
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1 When coatings are applied by brush, brushes shall be pure hair bristles and shall be of a
style and quality that will permit proper application of the material. Flat brushes shall not be
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more that 100 mm wide. Brushes shall be approved by the Engineer. Extending handles
shall not be used. M
2 Brushing shall be affected so that a smooth coat, as nearly uniform in thickness is obtained.
There shall be no deep or detrimental brush marks.
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3 Paint shall be worked into all corners and crevices. When applying solvent type coating, care
shall be taken to prevent lifting of previous coats.
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8.3.11 Shop Coatings

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1 Electrical and mechanical equipment shall be coated and painted as specified in this Part and
in Section 9. The location of coating and painting; i.e., in the shop or on Site, shall be as
specified in Section 9.
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8.3.12 Site Painting of Manufactured Items

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1 Steel pipework or fabrication shall be works cleaned and painted in accordance with
Tables 8.1 through 8.4. Total dry film thickness shall be in accordance with the location of
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surfaces of painted as specified in Table 8.2
2 Steel, cast or ductile iron encased in concrete (chamber walls and anchor blocks) shall be
prepared and coated as specified under Tables 8.1 through 8.4.
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3 Non-ferrous parts shall be protected using the same finishing system as that specified in
Tables 8.1 through 8.4 for the adjacent ferrous metal structure.
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4 When any coating which has been applied at a manufacturer’s works is considered by the
Engineer to be unsound or incompatible with the specified system, it shall be rejected. The
surfaces shall be recoated to a finish satisfactory to the Engineer.
5 When the Engineer’s Representative does not require the removal of the manufacturer’s
coating the equipment shall be solvent cleaned.
6 Hard baked finishes shall be abraded or softened by application of a strong solvent.

7 All polished and bright parts shall be coated with an approved rust preventative before
despatch and during erection, and this coating shall be cleaned off and the parts polished
before being handed over.
8 Manufactured items such as pumps motors, compressors, air vessels, conduits, etc. shall be
coated at works to the specification laid down for the environment in which they are to
operate. If this is impractical they may be paint coated to the manufacturer’s standard but
when on site the Contractor shall apply a sealing paint and top coats specified in Table 8.1 to
Table 8.4. Final site painting shall be in accordance with Table 8.1 to Table 8.4. The site
coating shall be 150 microns minimum dry film thickness (DFT).
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9 Pre-treatment and primers shall be suitable for the metal concerned and to BS 5493. Dry
film thickness shall be a minimum of 200 microns for all conditions.
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8.3.13 Site Application
1 Protective coverings shall be used to protect surfaces, fixtures, and equipment. Care shall be
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exercised to prevent paint from being spattered onto surfaces from which such paint cannot
be removed satisfactorily. Surfaces from which paint cannot be removed satisfactorily shall
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be painted or repainted as required to produce a finish satisfactory to the Engineer.
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2 Upon completion of the work, staging, scaffolding and containers shall be removed from the
site in an approved manner. Paint spots, oil or stains upon adjacent surfaces shall be
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removed to the satisfaction of the Engineer. No paint, solvents, rags or other materials used
by the Contractor shall be disposed of in any manner or location except as approved by the
Engineer. The Contractor is specifically cautioned to prevent paint of solvents to be in
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contact with plants or liquid streams.

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8.3.14 Epoxy Coating Work

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1 In addition to the general requirements of this specification the following shall apply to epoxy
coating works:
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(a) illumination at work site the satisfaction of the Engineer’s Representative

(b) forced draught ventilation to the approval of the Engineer shall be used wherever
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required for the needs of personnel or for drying out surfaces

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(c) operatives shall work in pairs.

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2 The Contractor shall demonstrate his methods equipment and materials before any work
commences. Samples areas of substrate shall be prepared and coated as required by the
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Engineer and for his approval.
3 There shall be strict control of surface cleanliness between primer and epoxy coating and
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between coats of the same type. Vacuum removal of dust and sand shall be employed and
contamination shall be removed as specified in appropriate surface preparation clauses
herein. Dirt or dust trapped in the painted surface shall be removed with suitable abrasive
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paper. The surface being painted shall be completely dry and free of visible moisture
throughout the operations.
4 The paint shall be applied only to clean dry primed or previously coated surfaces. Any thick
runs or collections of paint shall be removed before they harden.
5 Not less than two coats shall be applied over the primer by airless spray; not less than three
by brush.
6 Each coat shall be distinctly different in colour from the primer or previous coat. The colour
of the final coat shall be as required by the Engineer. Each coat shall be seen to have
completely covered the preceding coat without “misses” or pinholes or any areas visibly low
in thickness. A high voltage pinhole detector shall also be used to determine the integrity of
the coats.
7 The manufacturer of the coating shall stipulate primer and epoxy recoat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a maximum
tolerance of +4 h. Where this is exceeded, the surfaces to be recoated shall first be suitably
abraded to remove gloss and provide a key.
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8 Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness.
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8.3.15 Epoxy Coatings for Concrete and Rendered Surfaces
1 No priming shall commence until the moisture content of the cementitious surface is less
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than 5 % measured by instruments approved by the Engineer.
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2 Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed
1 % on the concrete scale of the instrument when the probe tips are held against such
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painted surfaces just prior to recoating.
3
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The primer shall be applied by suitable nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete.
Excess shall be removed by the most suitable means before application of the high build
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epoxy.
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4 The Engineer may approve an alternative application method where the Contractor can
demonstrate a suitable technique.
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5 The total dry film thickness of the paint layer shall have a minimum value of 0.75 mm.
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6 Whenever the Paint Inspection Gauge has been used and wherever the coating has been
otherwise damaged for 50 mm around such damage the surface shall be abraded and the
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area touched in with not less than two thick applications to restore the coating integrity and
thickness to that specified.
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7 Adhesion tests will be carried out on the cured coating surface using the test equipment
supplied under the Contract in accordance with the best practice. The resulting test
specimens shall show no indication of poor adhesion to the substrate, residual laitance or
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intercoat adhesion weakness.
8 Where required in the Project Specification or on a written request by the Engineer, the
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following instruments shall be provided for the Engineer sole use for the duration of the
Contract:
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2
(a) one adhesion tester (0-35 kg/cm )
(b) one DC high voltage Holiday detector No. 105
(c) one paint inspection gauge
(d) one moisture meter.
8.3.16 Galvanising and Other Finishes of Metals
1 Galvanising and other finishes of metals shall be carried out as specified in Parts 3 and 6 of
Section 8.
1 The Contractor shall conduct dry film thickness (DFT) measurements and other inspections
of all painted work, on completion of which the Engineer will make his own measurements,
examinations and inspections. If painted works are found unsatisfactory, the contractor shall
carryout remedial works as necessary at his expense and the works shall be retested by the
Engineer until such time the works are found satisfactory.
2 The Contractor shall provide and maintain two sets of the following inspection devices in
good working condition until final acceptance of painting and coating. One set shall be for
the Contractor’s use and the other for the sole use of the Engineer. On final acceptance of
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painting and coating, the inspection devices will be handed back to the Contractor.
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(a) Svensk Photographic Standard in accordance with SIS 055900
(b) non-destructive magnetic-type DFT gauge
(c) wet fill thickness combs
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(d) surface profile meter
(e) non-destructive type electrical holiday detector
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(f) low-voltage detector of the wet-sponge type and a non-sudsing type wetting agent, for
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testing discontinuities and voids in epoxy and thin film coatings
(g)
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high-voltage, low-current, spark type detector for electrical inspection of coal-tar
enamel only
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(h) maximum and minimum thermometer
(i) hygrometer
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(j) flow cup type B No. 4 and timer.

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END OF PART
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Part 10: Pipeline Cleaning and Inspection Survey
10 PIPELINE CLEANING AND INSPECTION SURVEY .................................... 2
10.1 GENERAL ...................................................................................................... 2

10.1.1 Scope 2
10.1.2 References 2
10.1.3 Submittals 2
10.1.4 Specialist Subcontractor 3
10.1.5 Programme of Work 3
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10.1.6 Topographic Survey of Sewers 4
10.1.7 Safety Requirements 4
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10.2 SEWER CLEANING ...................................................................................... 6
10.2.1 Scope 6
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10.2.2 Cleaning of Sewer Pipelines 7
10.2.3 Jetting 8
10.2.4 Winching 9
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10.2.5 Bucketing 9
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10.2.6 Balling or Kiting and Pipeline Internal Gauging 9
10.2.7 General Cleanliness of Areas during Sewer Cleaning M 9
10.3 SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING .......... 10
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10.3.1 Scope of Work 10
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10.3.2 Survey Requirements 10

10.3.3 Survey Equipment 11
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10.3.4 Survey Vehicle 13

10.3.5 Photographs 14
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10.3.6 Site Coding Sheets 14

10.3.7 Excavation 15
10.3.8 Survey Reporting 15
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10.4 OVERPUMPING AND FLOW DIVERSION ................................................. 16

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10.4.1 Source of Flow 16

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10.4.2 Pipe Stoppers 17

10.4.3 Stopping Off Flow 17
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10.4.4 Pumping Plant 17

10.4.5 Sewage Flooding 17
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10.4.6 Overpumping of Flow 18

10.4.7 Temporary Diversion of Flow 18
10.4.8 Entrances to Private Properties 18
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10.4.9 Odour and Noise Control During Flow Diversion and Overpumping 18
10.5 CONTRACTOR’S QUALITY CONTROL PROCEDURE .............................. 18
10 PIPELINE CLEANING AND INSPECTION SURVEY

10.1 GENERAL
10.1.1 Scope
1 This Part includes the specification for all work necessary to clean and carry out inspection
surveys of sewerage pipelines. The specification applies equally to the cleaning and
inspection survey of surface water and ground water pipelines.
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This Section
Part 1, General
Part 2, Earthworks
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Part 11, Sewer Rehabilitation
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Section 1, General.
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10.1.2 References M
1 The following document is referred to in this Part:
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Water Research Centre (WRC) Manual of Sewer Condition Classification
Water Research Centre (WRC) Sewer Rehabilitation Manual
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10.1.3 Submittals
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1 The Contractor shall submit complete data and details for pipelines cleaning and inspection
survey for the Engineer’s approval as follows:
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(a) programme of work, detailed method statement, and schedule of equipment to be

used on the project, general plant and specialist equipment
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(b) proposed methods of flow diversion and overpumping

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(c) specific data for the proposed specialist equipment before beginning any sewer
cleaning and inspection as follows:
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(i) original catalogues for all the proposed specialist equipment, which complying
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with the Specifications. These catalogues shall be considered as an integral

part of the Contractor’s method statement. All equipment to be provided for
sewer cleaning and closed circuit television (CCTV) survey and sonar scanning
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shall be reliable and in good working condition

(ii) typical video recordings preferably on CD ROM of similar work carried out
previously by CCTV camera and sonar scanner. Such recordings, if acceptable,
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will be retained by the Engineer as the standard for appraisal of subsequent

recordings
(iii) video graphic printer
(iv) still pictures in digital format (Tiff, JPEG) for computer data storage and
retrieving
(d) specific data to be submitted while carrying out and at the completion of the work:
(i) site coding sheets as designated under Clause 10.3.6 in this Part
(ii) the master and a copy of each video recording as designated in Clause 10.3.2 in
this Part
(iii) still colour pictures using video graphic printer of the inside of sewers,
manholes, inspection chambers, and grease and oil interceptors, and the
interior of pumping stations as required and as specified in Clause 10.3.5 of
this Part.
2 The Contractor shall submit a method statement to the Engineer for approval four weeks in
advance of commencing activity on site. The method statement shall comprise but not
necessarily be limited to:
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(a) Equipment set-up and locations of proposed access points
(b) Anticipated cut off periods for services
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(c) Procedures for notifying affected residences and businesses
(d) Procedures for verification of active services
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(e) Procedures for complying with traffic control
(f) Procedures for seeking permits to work.
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(g) Safety procedures in particular working with scaffolding and entering confined spaces.
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10.1.4 Specialist Subcontractor M
1 The Contractor shall employ an approved specialist subcontractor designated in the contract
document.
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2 The Contractor shall provide the following information on sewer cleaning and inspection
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survey contracts carried out by the proposed subcontractor during the last five years:
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(a) project location

(b) name and address of client
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(c) start and completion dates

(d) cost of the works undertaken by the subcontractor
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(e) length, diameter and material of sewers

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(f) reference letter from the client or engineer

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(g) a sample document of the reports produced for at least two projects.
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3 All operators employed by the subcontractor shall be fully skilled in the specified works.
4 The operator for interpreting the video recordings and preparing the site coding sheets shall
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be fully conversant with picture interpretation, defect coding and classification. A copy of the
operator’s current certificate of qualification for sewer surveys and fault classification issued
by Water Training International of the U.K. or an equivalent body for the types of sewers to be
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inspected shall be submitted to the Engineer for approval before beginning the survey. If the
Engineer determines that the Operator’s qualifications and experience are not acceptable,
the Contractor shall provide an acceptable replacement before beginning the survey.
10.1.5 Programme of Work
1 The sewage pipelines may be frequently surcharged and ready access to them may not be
available. The Contractor shall make due allowance for such disruptions in his programming
of operations. The Contractor shall cause minimum disruption to the utilisation of the
pipelines and the period of overpumping shall be kept to the minimum necessary. Before
starting the cleaning and inspection survey in any sewer length, the Contractor shall submit
an applications to CED Drainage Division O & M Section for a permit to work in the sewers.
10.1.6 Topographic Survey of Sewers
1 A topographic survey of the pipelines to be cleaned shall be carried out by the Contractor and
a schedule provided to the Engineer. Some manhole covers may be buried under
landscaping, debris, or the surface of roads, footpaths, or other pavements. These manholes
shall be located by the Contractor on the basis of the Employer’s record drawings using
appropriate techniques and apparatus. The topographic survey of the sewer system shall
include resurveying where affected by any rehabilitation works on completion of the sewer
cleaning and inspection surveys as directed by the Engineer.
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2 The survey shall include details of manholes, chambers, and oil and grease interceptors
including topographic levels of covers and inverts, locations and co-ordinates.
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3 The Contractor shall locate accurately and survey all junctions and lateral connections into
manholes, or directly into sewers, whether or not the existence or location of such junctions
and lateral connections are shown on the Employer’s record drawings.
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4 The Contractor shall survey the original ground surface, taking levels at 50 m intervals or as
directed by the Engineer along the route of the sewer, determine existing pipe diameters and
invert levels, and the details shall be recorded in a schedule to the Engineer’s approval.
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These details shall, when finally and mutually agreed, be signed by the Contractor and
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authorized by Engineer as truly representing the configuration of the particular areas.
10.1.7 Safety Requirements

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1 The Contractor’s attention is drawn to the hazards involved in working in confined spaces
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including sewers, sewer manholes, inspection chambers, wet wells, pumping stations and
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ancillary structures. The Contractor shall be responsible for ensuring that adequate
precautions are taken to ensure safe working conditions.
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2 The Contractor shall give evidence of having carried out training in avoiding the following
risks associated with working in confined spaces in sewerage pipelines:
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(a) presence of toxic, flammable and explosive gases

(b) persons falling
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(c) falling objects

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(d) drowning
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(e) infection.
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3 Training shall include the following:

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(a) definition of confined spaces

(b) atmospheric hazards
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(c) purpose and practical use of gas monitoring equipment

(d) practical use and maintenance of safety equipment such as breathing apparatus,
safety harnesses, life lines and lifting frames
(e) personal protective equipment such as hard hats, gloves and safety boots
(f) health hazards
(g) hygiene procedures
(h) basic first aid procedures
(i) pre-entry procedure
(j) entry procedure
(k) exit procedure

(l) rescue procedure.
All training courses shall involve both class room instruction and hands-on practical training
which should include both entry and rescue drills.
4 Safety and Protective Equipment. The Contractor shall safeguard his work force against
physical injury caused by falling or being struck by falling objects. Precautions shall include,
but are not limited to, the provision of the following equipment for each person working in
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confined spaces:
(a) safety helmet with chin guard
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(b) safety boots
(c) safety harness
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(d) PVC gloves/gauntlets
(e) overalls
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(f) rubber boots
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(g) ear, eye, and face protection, where applicable.
5
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In addition to the above, each gang working in a confined space shall have with them:
(a) four sets of 15 m life lines with spring shackle one end, eye at other
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(b) portable ladder

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(c) lifting frame complete with ropes and shackles for hand operation
(d) powerful hand lamp, explosion proof (intrinsically safe)
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(e) ventilation blower together with portable generator and flexible ducting
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(f) position pressure respiration face masks with associated portable compressor or air
line system supplying air via compressed cylinders
(g) gas detectors capable of detecting both high and low oxygen, hydrogen sulphide and
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methane gas explosion proof (intrinsically safe).

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6 All safety and protection equipment shall be regularly maintained and inspected by a
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competent person. Gas monitors shall be calibrated in accordance with the manufacturer’s
recommendations and a certificate issued with the date of calibration.
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7 Each group of workers engaged in working in sewers, manholes, pumping stations and
ancillary structures shall be provided with, and shall be familiar with the operation of gas
testing equipment suitable for checking hydrogen sulphide, combustible gases, and lack of
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oxygen. Before entering confined spaces the atmosphere within such spaces shall be tested
and certified as safe for entry by the responsible person to ensure that there is no build up of
hydrogen sulphide or combustible gases, nor lack of oxygen. When working in sewers where
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accumulation of sludge or silt exists, the Contractor's attention is drawn to the fact that, when
disturbed, sludge may release toxic gases. Adequate ventilation facilities shall be provided
and continuous monitoring shall be made while work is in progress in live sewers or
structures containing sludge or silt.
8 Should anyone working in a confined space complain of nausea or dizziness, all personnel
shall be removed from that location immediately. Work may resume only when it is certified
safe to do so, using breathing apparatus if necessary.
9 The Contractor shall safeguard his work force against health hazards while working in sewers
and inform his work force of the dangers of bacterial infection while working in a sewage
contaminated environment, and shall impress upon them the importance of personal
hygiene. All members of the work force shall be fit, and everyone who will be expected to
work in sewers shall not suffer from:
(a) Any heart defect.

(b) Any history of fits or blackouts.
(c) Deafness or loss of balance.
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(d) Claustrophobia.
(e) Recurrent back ailments.
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(f) Shortage of breath on light exertion.
10 All members of the work force shall be vaccinated against tetanus, typhoid, paratyphoid,
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hepatitis A and B and cholera, and shall each carry an up-to-date medical record on their
person. The Contractor shall provide a medical certificate of fitness for all his personnel.
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11 The Contractor shall keep personal hygiene and emergency equipment within easy access of
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each working group. Emergency equipment which shall include but not be limited to:
(a) Barrier cream.

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(b) Disinfectant.
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(c) First-aid kit with eye bath.
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(d) Stretcher.
(e) Life lines 15 m long with spring shackle one end, eye at other.
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(f) Lifting harnesses.

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(g) Two sets of breathing apparatus with air bottle.
12 The address and telephone number of the nearest hospital with emergency facilities shall be
posted in each working location.
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13 The Contractor shall be solely responsible for liability for any claim or legal action arising as a
result of an accident and shall not be absolved of any liability under the Contract for his
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having conformed to the above requirements.

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14 The Contractor shall provide and erect approved safety barriers around all unattended open
manholes and cover them with suitable temporary steel sheets. Advance warning notice road
signs shall be erected at least 50 m in front and behind the area being worked in one day. At
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the end of each day works all manhole covers shall be replaced.
10.2 SEWER CLEANING

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10.2.1 Scope
1 The cleaning of sewer pipelines and appurtenances includes but is not limited to the following
elements:
(a) location of manholes and chambers using suitable detection techniques and removal
of overburden where necessary
(b) cleaning of manholes and chambers with either or both water jetting or wire brushing
or other means approved by the Engineer
(c) removal of any grit and debris from manhole bases and benching
(d) providing cutoff walls and overpumping where necessary

(e) water jetting including vacuum suction of debris
(f) bucket and winch dredging, balling, kiting, pipeline internal gauging, or any other
cleaning process as approved by the Engineer
(g) flushing with water
(h) removal of all sand, grit and debris jetted or dredged from the sewers and disposal of
same to a disposal site required by the Engineer
(i) controlling of odour and nuisance arising out of rehabilitation works, flow diversion or
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overpumping.
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10.2.2 Cleaning of Sewer Pipelines
1 Cleaning of sewers and manholes before inspection surveys shall include one or more of the
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above operations. The Contractor should note that pipelines, manholes, may have structural
defects cracks etc., and may have been completely filled with sand, grit, sediment and other
debris and the requirement to accurately measure the vertical inside diameter of the sewer
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necessitates that the invert of the sewer to be free of all sediment. The Contractor shall allow
for the removal of all such material and disposal of same to a disposal site approved by the
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Engineer. Cleaning of sewers shall progress downstream.
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Sewer cleaning shall be thorough and shall only be carried out by methods approved by the
Engineer to remove all deposits, foreign matter, solid or semi-solid and hard intruding
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material and all other debris including sand, silt, slime, sludge, sediment, grease, roots, loose
flaky or soft pipe wall materials, loose concrete from walls and underside of cover slabs and
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benching of manholes from within sewers and manholes. The liquid biological element of the
sludge may be returned to the sewer system after suitable filtering methods to be agreed with
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the Engineer.
3 Where cast iron junction pieces have been used, the Contractor shall ream out or grind off
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the corrosion products to produce a pipe of diameter equal to the adjacent pipes. Care shall
be taken to grind off all burrs which may otherwise puncture in-situ lining tubes during
subsequent renovation works.
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4 Pump station wells shall be cleaned where necessary to permit pipeline cleaning.
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5 The designated sewer/manhole sections shall be cleaned using hydraulically propelled, high-
velocity jet, or mechanically powered equipment. The equipment and methods selected shall
be satisfactory to the Engineer. The equipment shall be capable of removing dirt, grease,
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rocks, sand, and other materials and obstructions from the sewer lines and manholes. If
cleaning of an entire section cannot be successfully performed from one manhole, the
equipment shall be set up on the other manhole and cleaning again attempted. If, again,
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successful cleaning cannot be performed or the equipment fails to traverse the entire
manhole section, it will be assumed that a major blockage exists and the cleaning effort shall
be temporarily abandoned until further notification by the Engineer.
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6 If the Contractor’s cleaning equipment becomes lodged in a sewer it shall be removed by the
Contractor at his own expense. This shall include excavation, repair of sewer, backfill and
surface restoration.
7 All sludge, dirt, sand, rocks, grease, and other solid or semi-solid material resulting from the
cleaning operation shall be removed at the downstream manhole of the section being
cleaned. Passing material from manhole section to manhole section, which could cause line
stoppages, accumulations of sand in wet wells, or damage pumping equipment, shall not be
permitted.
8 Roots shall be removed in the designated sections where root intrusion is a problem. Special
attention should be used during the cleaning operation to assure almost complete removal of
roots from the joints. Procedures may include the use of mechanical equipment such as
rodding machines, bucket machines and winches using root cutters and porcupines, and
equipment such as high-velocity jet cleaners.
9 All solids or semi-solids resulting from the cleaning operations shall be removed from the site
and disposed of at an approved off-site disposal facility. All materials shall be removed from
the site no less often than at the end of each workday. Under no circumstances will the
Contractor be allowed to accumulate debris, etc., on the site of work beyond the stated time,
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except in totally enclosed containers and as approved by the Engineer.
10 Acceptance of sewer line cleaning shall be made upon the successful completion of the
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television inspection and shall be to the satisfaction of the Engineer. If CCTV inspection
shows the cleaning to be unsatisfactory, the Contractor shall be required to reclean and
reinspect the sewer line until the cleaning is shown to be satisfactory.
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10.2.3 Jetting
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1 Jetting shall be carried out using motorised jetting vehicles specially designed for the work
involved and complete with an integral water tank. Jetting shall be carried out at an
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appropriate water pressure such that no damage to pipes occurs. The jetting pump shall
have the capability to vary the water pressure at the jetting nozzle and be equipped with a
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sufficient length of suitable armoured bore hose and jetting heads to accommodate all
possible working conditions and pipe size in the sewer system. Jetting pressure to be
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2 Brackish water shall not be used for cleaning. Treated sewage effluent may be used subject
to the approval of the Engineer.
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3 The hose shall be mounted on a power operated drum reel having variable speed and
direction controls and a meterage indicator. The hose shall be equipped with a variety of
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nozzles totalling 15 to 30 including rear jets only, rear plus forward jets, rear plus side jets,
and other such configurations necessary to ensure adequate cleaning of the pipeline.
Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.
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4 During all jetting operations the channel of the downstream sewer manhole shall be provided
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with a cut off wall and all decumulated grit and debris shall be removed.
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5 Hydraulically propelled equipment shall be of a movable dam type and be constructed in such
a way that a portion of the dam may be collapsed at any time during the cleaning operation to
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protect against flooding of the sewer. The movable dam shall be the same diameter as the
pipe being cleaned and shall provide a flexible scraper around the outer periphery to ensure
removal of grease. Sewer cleaning balls or other equipment which cannot be collapsed shall
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not be used.
6 Mechanically powered rodding machines shall be either a sectional or continuous rod type
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capable of holding a minimum of 200 m of rod. The rod shall be specifically heat-treated
steel. To ensure safe operation, the machine shall be fully enclosed and have an automatic
safety clutch or relief valve. Buckets, scrapers, scooters, porcupines, brushes and other
mechanical equipment may also be utilised.
7 All equipment and devices shall be operated by experienced personnel so that sewer lines
are not damaged in the process of cleaning. When hydraulically propelled tools (which
depend upon water pressure to provide their cleaning force), or tools which retard the flow in
the sewer line are used, all necessary precautions shall be taken to ensure that the water
pressure created does not damage or cause flooding of property being served by the sewer.
When possible, the flow of sewage in the sewer shall be utilised to provide the necessary
pressure for hydraulic cleaning devices. When additional water from water mains is
necessary to avoid delay in normal work procedures, the water shall be conserved and not
used unnecessarily.
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10.2.4 Winching
1 The jetting machine shall incorporate a power-driven cable drum having not less than 200 m
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of 13 mm steel cable. The cable drum shall be mounted on an A-frame, fixed to the vehicle
or trailer high enough off the ground to allow the bucket to be lifted above ground level. The
backpull machine shall incorporate a power-driven cable drum with not less than 200 m of
nylon rope or light steel cable. The working machine shall have a swinging arm fixed to the
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top of the A-frame. The swinging arm shall be capable of lifting the bucket clear of the ground
and rotating it away from the manhole for emptying. A chute with rollers and a shaker bar
may be used subject to the approval of the Engineer.
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10.2.5 Bucketing
1
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A range of bucket sizes shall be provided to suit the various pipe diameters. The buckets
shall be cylindrical in cross-section with bails at each end having centre eye lugs and shall be
of the clam shell type with the bottom made of two hinged halves such that when the bucket
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is pulled in the reverse direction, bottom first, the jaws open permitting debris to pass
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through. When the bucket is pulled forward the jaws shall close, thereby retaining any
material in the bucket or which subsequently enters. Both ends of the bucket shall be able to
dig into and scrape sediments and debris from the sewer invert.
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10.2.6 Balling or Kiting and Pipeline Internal Gauging

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1 Balls shall be of inflatable rubber or other material approved by the Engineer having an
outside spiral thread and a swivel connection. With a hydraulic head differential of
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approximately 0.6 m, the ball shall rotate rapidly and produce a scouring jet on its periphery.
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2 Suitable cable or rope shall be attached to the swivel connection fed from a cable drum
mounted on an A-frame complete with braking facilities. A manhole jack and cable guide
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roller shall be used to feed the cable into the sewer. If the flow in the sewer is insufficient to
produce adequate scouring velocity, the Contractor shall provide the additional supply of
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water to overcome the deficiency.
3 Kites may be used as an alternative to balls for sewers 600 mm diameter and above.
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4 Pipeline internal gauges shall not be used unless attached to lines in both upstream and
downstream manholes.
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5 During all balling, kiting or gauging operations, the channel of the downstream manhole shall
be provided with a cut off wall and accumulated debris removed.
6 Sewer cleaning balls or other equipment which cannot be collapsed shall not be used.
10.2.7 General Cleanliness of Areas during Sewer Cleaning
1 The Contractor shall take all necessary precautions to ensure that during the sewer cleaning
operations there is no spillage of sewage and debris onto the streets and other areas. When
spillage occurs, the Contractor shall immediately remove all spillage and clean all surfaces to
their original condition.
10.3 SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING
10.3.1 Scope of Work
1 CCTV survey and sonar scanning shall be carried out only after satisfactory cleaning of the
pipeline as specified in Clause 10.2 of this Part. The CCTV survey and sonar scanning shall
include but not be limited to:
(a) Production of colour video tape recording on compact disc (CD) and coding.
(b) Accurate profiling of the cross-section of sewers and measurement of deflections.
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(c) Still colour pictures from a video graphic printer of the inside of sewers and manholes,
inspection chambers and grease and oil interceptors, as directed by the Engineer.
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(d) Recording the complete survey on a computer database in accordance with WRC
Manual of Sewer Condition Classification.
(e) Pictures to be printed in a digital format (Tiff) for computer data storage and retrieval.
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10.3.2 Survey Requirements
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1 The rate of travel of the camera shall be such as to enable all details to be extracted from the
video tape recording. M
2 The axis of the camera shall be arranged to coincide with the centreline of the pipe.
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3 The picture transmitted by the CCTV scanning camera (a scanning camera which can view
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lateral connections to sewers) and sonar scanner shall be free from interference and loss of
vertical and horizontal hold. The picture shall be in focus, properly illuminated, of good
contrast and without distortion. If vision is obscured at any time by the fouling of the lens, or
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lighting system, or if travel is impeded by obstructions, the camera shall be withdrawn and the
defect rectified immediately.
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4 The Contractor shall record the complete survey on a video tape format conforming with the
recording equipment manufacturer’s specification. The recording shall provide a continuous
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display of data on the monitor screen comprising the following information:

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(a) automatic update of camera meterage

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(b) date, day, month and year

(c) direction of survey - upstream or downstream
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(d) gradient of sewer

(e) nominal diameter of sewer and the actual measured horizontal, vertical and diagonal
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diameters at close intervals as directed by the Engineer

(f) manhole/pipe type length reference number
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(g) sewer use

(h) time of start of survey
(i) location reference.
5 The video recording shall be stopped whenever the camera is stationary for more than
5 seconds and shall have manual override capability.
6 The completeness of the video tapes shall be an accurate record of the sewer system which
identifies and locates sewer defects, provides information that permits accurate analysis of
the cause, extent, nature and severity of sewer deterioration and the measurement of
horizontal, vertical and diagonal diameters of sewer and their locations.
7 Portions of video tape marred by interference, or otherwise unacceptable shall be erased and
the relevant portion of sewer shall be resurveyed and rerecorded. The Engineer’s decision as
to the acceptability of any video recording shall be final.
8 Still colour photographs as designated under Clause 10.3.5.
9 The photographic negatives, the master video tapes, and a copy of the video tapes shall be
handed over to the Engineer and shall become the property of the Employer.
10 If a self-propelled camera is used, it shall incorporate features to enable it to be winch drawn
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without affecting the quality of the video recording.
11 The location of any conditions that may result in a limitation of rehabilitation techniques that
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could be used and/or prevent proper installation of designated rehabilitation materials in the
pipelines shall be noted. The Contractor shall propose corrective measures and/or alternative
methods of rehabilitation for the approval of the Engineer.
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10.3.3 Survey Equipment
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1 The CCTV survey and sonar scanning equipment shall be modern and of advanced design
and shall be tested and calibrated immediately before beginning work. The equipment shall
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be tested as designated herein by the manufacturers or an approved independent test
laboratory at intervals of not more than 6 months. Original certificates of compliance with the
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specifications of this Part shall be submitted to the Engineer before beginning work. The
equipment shall include but not limited to the following:
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(a) CCTV camera and sonar scanner suitable for mounting on the same trolley as and
when required
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(b) colour TV camera with swivel, lift and radial device and able to focus on points of
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interest
(c) camera light head assembly with sufficient illumination for the diameter of sewer
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pipes
(d) camera wheeled/tracked crawler assembly, self-propelled/flexible-shaft driven and
remotely operated with forward, reverse, left, right stop and load indication
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(e) cable reel of minimum 200 m cable length with fully automatic and microprocessor
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controlled cable handling facility

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(f) power winch with either lockable or ratcheted drums

(g) CCTV/Sonar central control units
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(h) colour TV monitor

(i) high-resolution scanning device including high speed pipe profiler and software to
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interpret the signals

(j) video cassette recording system with audio video information system
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(k) all standard and optional accessories recommended by the manufacturers.
2 The picture quality of the camera shall be tested using the Marconi Resolution Chart No. 1 or
equivalent clearly defined with no tinting to show white, yellow, cyan, green, magenta, red,
blue and black.
3 The quality of the CCTV electronics, camera and monitor shall be such that the following
criteria are satisfied and if any of the criteria are not met during the survey the lengths of
sewer so affected shall be resurveyed at the Contractor’s expense:
(a) Shades of Grey. The grey scale shall show equal changes in brightness ranging from
black to white with a minimum of five stages
(b) Colour. With the monitor control adjusted for correct saturation, the six colours plus
black and white shall be resolved with the primary and complementary colours in
order of decreasing luminance. The grey scale shall appear in contrasting shades of
grey with no tint
(c) Linearity. The background grid shall show squares of equal size, without
convergence or divergence over the whole picture. The centre circle shall appear
round and have the correct height/width ratio within 5 %
(d) Resolution. The live picture shall be clearly visible with no interference and capable
of registering a minimum number of TV lines/picture height lines. The resolution shall
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be checked with the monitor colour control turned down. For tube type cameras this
shall be 350 lines and for CCD type cameras it shall be 250 lines
(e) Colour Consistency. The colour on the live picture and that on the video picture shall
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be consistent with that described for the Marconi Resolution Chart No. 1.
4 The camera shall be capable of taking clear pictures in any direction; i.e., 90  to the left and
90  to the right (total 180  in horizontal axis) and also 360  in the circumference of the pipe
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without using extra revolving mirror attachment.
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5 The camera shall continuously transmit distance at each meter length, electronically matched
to the movement of the camera with a maximum tolerance of  0.1 % on the control TV
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monitor and the resultant video tapes.
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The camera shall indicate the degree of inclination of the sewer line with tolerance of 0.2 %
on the TV monitor with a printout of the slope.
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7 The camera crawler assembly shall be adjustable for deployment in sewers of varying
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diameters. When required, both sonar scanning and CCTV equipment shall be mounted on
the same crawler assembly.
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8 The video tape recording of the transmission for CCTV and Sonar scanning units shall be
provided to accurately record on video tapes, of quality approved by the Engineer. In the
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central control unit, the operator shall have remote facilities to control the camera, the cable
drum and power winch.
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9 Each unit shall carry sufficient number of guides and rollers to ensure that, when surveying all
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bonds are supported away from pipe and manhole structures and all CCTV cables and lines
used to measure the camera’s location within the sewer are maintained in a taut manner and
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set at right angles, where possible, to run through or over the measuring equipment.
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10 At the start of each and every working shift, the camera shall be positioned centrally and at
right angles to the test card at a distance where the full test card just fills the monitor screen,
ensuring that the edges of the test card castellation coincide with the edges of the horizontal
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and vertical scan (raster). The card shall be illuminated evenly and uniformly without any
reflection. The illumination shall be to the same colour temperature as the colour
temperature of the lighting that will be used on the CCTV survey equipment in the pipe. The
test shall be recorded for subsequent use by the Engineer, the recording time to be at least
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30 seconds. The type of camera used is to be identified on the test recording. The recording
must show the camera being introduced into the test device and reaching its stop position.
Other test devices may be used subject to approval by the Engineer.
11 The Contractor shall note that the Engineer may periodically check both the live and recorded
picture colour consistency against the colour bar. Any differences will necessitate re-survey
of the lengths affected at the Contractor’s expense.
12 The adjustment of focus and iris shall allow optimum picture quality to be achieved and shall
be remotely operated. The adjustment of focus and iris shall provide a minimum focal range
from 50mm in front of the camera’s lens to infinity. The distance along the pipe in focus from
the initial point of observation shall be a minimum of twice the vertical height of the pipe. The
illumination must be such as to allow an even distribution of the light around the pipe
perimeter without the loss of contrast, flare out of picture or shadowing.
13 Where the CCTV survey equipment is towed by winch and bond through the pipe, all winches
shall be stable with either lockable or ratcheted drums. All bonds shall be steel or of an
equally non-elastic material to ensure the smooth and steady progress of the CCTV survey
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equipment. All winches shall be inherently stable under loaded conditions.
10.3.4 Survey Vehicle
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1 The CCTV and sonar scanning vehicles shall be equipped with the following three separate
compartments:
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(a) driver’s cabin
(b) operator and viewer’s compartment (seating for minimum three persons)
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(c) Camera and sonar scanner equipment storage compartment.
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2 The operator and viewer’s compartment shall be insulated against noise and extremes in
temperature and be provided with means of controlling external and internal sources of light
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in a manner capable of ensuring that the monitor screen display complies with the specified
requirements.
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3 The equipment storage compartment shall have adequate space for equipment, both
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operational and stored. Equipment used in sewers shall not be stored in compartment.
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4 The vehicle shall be equipped with air-conditioner for the driver’s cabin and the operator’s
room. A wireless communication system between the operator inside the vehicle and the
helper outside the vehicle shall be provided.
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5 The vehicle shall be complete with all equipment and apparatus necessary to carry out a
complete sewer inspection survey. Colour monitors, a sonar processor unit, replay and on-
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board reporting, video recorders, video printers, computers and computer printers to
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generate survey reports and data base shall be provided. The operator/viewer’s compartment
shall be designed for optimum productivity.
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6 The vehicle shall be equipped with the following road safety equipment:
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(a) a minimum of two amber regulation flashing beacons fixed at diagonal corners of the
vehicle, which shall operate continuously while the vehicle is stationary on the
highway in a working situation
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(b) traffic signs and cones, which shall be displayed in accordance with the
recommendations of the Traffic Police Section, with a minimum of:
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(i) four reflective boards: Arrow

(ii) two reflective boards: Men Working (in English and Arabic)
(iii) two reflective boards: Road Narrows (in English and Arabic)
(iv) 20 reflective cones
(v) 12 battery operated flashing road lamps.
(c) a sufficient number of bright coloured overalls with fluorescent over-jackets or belts,
which shall be worn by all operatives while working on roads.
7 Relevant safety equipment specified in Clause 10.1.7 shall be made available.

10.3.5 Photographs
1 After sewer cleaning and in parallel with the CCTV inspection, excellent quality still colour
photographs 90 mm x 130 mm with the date and submitted in TIFF format an album with
captions providing a detailed description, the precise location and reference numbers as
designated shall be taken of:
(a) the inside the sewer to show the typical conditions for each length of sewer. A
minimum of three photographs per manhole length shall be taken at every junction
piece, faulty joint, broken pipe, and other points of interest as directed by the
Engineer
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(b) the interior of each manhole, chamber and grease/oil trap. A minimum of three
photographs shall be taken of each structure showing the general extent of corrosion
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to the structure’s walls, bases, benching and the underside of cover slabs as directed
by the Engineer
2 Photographs shall be taken of the internal condition of the pipes at the beginning of a defect,
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at service connections and such other places as the Engineer shall direct. Where defects
exist at adjacent points, photographs should not be taken at intervals of less than 2m unless
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absolutely necessary to show the second defect. Where photographs are not otherwise
required, a general condition photograph shall be taken at every l0m.
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3 Photographs must clearly and accurately show what is displayed on the monitor which shall
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be in proper adjustment.
4 Photographs shall be clearly identified in relation to the location (minimum requirement

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manhole start and finish numbers or pipe length reference numbers) survey direction,
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chainage, photograph number, and date when the photograph was taken. The annotation
shall be clearly visible and in contrast to its background, shall have a figure size no greater
than 5mm, and be type printed. The annotation shall be so positioned as not to interfere with
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the subject of the photograph.

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5 Hard copy of the photographs shall be supplied in suitable A4 sized plastic holders and
bound in ring binders or lever arch files. The photographs shall be presented in chronological
order and each file shall contain a contents page providing clear cross-referencing to the
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report. The minimum requirements of the contents page shall be locations (district, street
name and road number), photograph numbers and dates when photographs were taken.
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10.3.6 Site Coding Sheets

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1 Site coding sheets detailing the condition of each pipe length and manhole shall be
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completed in the format of the WRC Manual of Sewer Condition Classification and as
approved by the Engineer. These sheets shall be submitted to the Engineer with the video
tape to which they refer. A draft copy of the coding sheets shall be submitted weekly to the
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Engineer for his approval. When requested by the Engineer, more frequent reports of
selected parameters shall be submitted.
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2 The site coding sheets shall be standardised to the approval of the Engineer to indicate the
following minimum requirements:
(a) location reference to sewer length concerned

(b) nominal diameter of sewer
(c) actual measured horizontal, vertical and diagonal diameters of sewer and their
locations, as a continuous computer printout at close intervals and as directed by the
Engineer
(d) date of survey
(e) direction of survey
(f) time of start of survey

(g) sewer gradient
(h) trial hole records
(i) coded reference to any defects encountered
(j) location of defects
(k) location of any junctions or laterals encountered
(l) location of any still photographs taken.
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3 In addition to the final report and any interim reports on a section of the pipe as defined
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above, the Contractor shall provide the Engineer with the following:
(a) One copy of the completed survey report coding forms at the end of each working
shift.
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(b) One copy of sheets containing the pipe reference number, distance, orientation and
deflection measurements of the pipes surveyed at the end of each working shift.
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(c) One copy of photographs and recordings on a weekly basis as the work progresses or
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as previously agreed with the Engineer in writing.
10.3.7 Excavation M
1 When directed by the Engineer, the Contractor shall excavate and expose sections of sewer
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for examination.
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2 The Contractor shall carry out such excavations expeditiously and shall break or expose the
sewer section upon removal from the trench for detailed physical examination and testing.
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3 Excavations shall be carried out in accordance with Part 2 of this Section.

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4 When directed by the Engineer, the Contractor shall reinstall the sewer section or replace the
sewer section with new pipe of same size and material in a manner to completely conform to
the original installation and shall backfill, compact and reinstate the excavation in accordance
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with Part 4 of this Section.

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10.3.8 Survey Reporting

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1 The Contractor shall complete the CCTV survey and sonar scanning in appropriate lengths
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as directed by the Engineer before handing over the records for that line. All records for a
particular length shall be handed over at one time unless directed otherwise by the Engineer
and all recordings on one tape shall be of the same length. The report shall include the
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following, all as designated herein:
(a) site coding sheets

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(b) correctly labelled video tapes of approximately one hour duration

(c) pictures on compact discs in a digital format (Tiff)
2 The report shall be completed using a computer based database with software that shall be
fully compatible with the Oracle database used by the Ministry of Municipal Affairs &
Agriculture’s ARC INFO GIS system and approved by the Engineer. One copy on a 3.5 inch
diskettes of all computer generated data shall be provided with the report. Four copies of
draft report shall be submitted for Engineer’s approval followed by final report incorporating
appropriate responses to the Engineer’s comments.
3 The Contractor shall enter the information obtained from the survey into a computer
database in accordance with the WRC manual of sewer classification which shall allow for
the storage, retrieval and analysis of this information. Furthermore the database shall link the
survey information with an electronic drawing of the pipeline which shall allow the viewing of
still images representative of the major problems identified by the survey.
4 The Contractor shall supply 2 copies of each recording in CD format.
5 The condition survey report shall include the following:
(a) Pipe condition classification in accordance with the WRC format.
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(b) Manhole/pipe length reference numbers.
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(c) Date of survey.
(d) Road name/location.
(e) Direction of survey.
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(f) Time of start of survey.
(g) Weather conditions.
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(h) Pipe dimensions.
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(i) Materials of construction. M
(j) Depth of flow.
(k) Profiling of pipe cross sections to give a complete circumferential profile and
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deflections within the pipe.
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(l) Clock position of all connections including meterage from manhole.

(m) Whether or not connections are dry and running.
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(n) Location and description of obstructions, structural defects, missing pieces of pipe,
open and/or offset joints, ovality, leakage or evidence thereof, corrosion, erosion,
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break-in connections, protruding connections, mineral deposits, roots, previous

repairs, sags and other abnormalities with respect to the pipeline’s condition with
counter distance in metres from the start manhole’s centreline.
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(o) Photographs as specified herein.

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(p) Recommendations, including options and alternative methods to extend the service life
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by a further 50 years by lining, replacement or other refurbishment.

(q) Estimated cost and programme for carrying out the recommendations.
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6 If the Engineer requires separate survey reports for any section of the survey or requires
some or all of the section to be grouped together in a single survey report he shall notify the
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Contractor accordingly.
10.4 OVERPUMPING AND FLOW DIVERSION

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10.4.1 Source of Flow
1 Manholes and sewers being worked on shall be completely isolated and by-passed such that
they do not contain any sewage. This shall be achieved by plugging, pumping and bypassing
or diverting the flow.
2 When flow in a sewer line is plugged, pumped and bypassed or diverted sufficient
precautions must be taken to protect the sewer lines from damage that might result from
sewer surcharging. Further, precautions must be taken to ensure that sewer flow control
operations do not cause flooding or damage to public or private property being served by the
sewers involved.
3 The Contractor shall submit his proposed method of overpumping or flow diversion to the
Engineer for approval.
4 The Contractor shall co-ordinate and agree all his activities on live facilities with the Drainage
Affairs Maintenance Department staff responsible for upkeep of the drainage system. A
signed Permit to Work shall be obtained from Maintenance Department prior to the
commencing the work.
10.4.2 Pipe Stoppers
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1 The flow shall be stopped off using pipe stoppers of a type approved by the Engineer. The
stopper shall be of circumferential compressible rubber rings fully inserted inside the pipe
before tightening. Inflatable type stoppers for sewers less than 300 mm diameter shall be of
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a type approved by the Engineer.
2 Stoppers shall be suitable for the sizes and classes of pipe in which they are used and must
not cause damage to existing pipes. Stoppers must be able to withstand the maximum
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possible differential head at each location and shall be fully restrained in accordance with the
manufacturer’s recommendations.
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3 The Contractor shall be solely responsible for maintaining such stoppers in good working
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condition and for the consequences of any failure thereof.
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Where a section of the sewerage system is isolated for work involving man-entry to the
isolated area, a minimum of two stoppers shall be used at each boundary location isolating
the area from the main sewer and subsidiary sewers. At least one of these stoppers at each
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location should be of an approved pneumatic type.

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10.4.3 Stopping Off Flow

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1 For the length of sewer being surveyed, the Contractor shall plug off the outlet of the
downstream manhole and the inlet to the upstream manhole. The next upstream manhole
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shall be used as a pumping sump with the outlet to that manhole also being plugged off.
2 All service connections discharging into the plugged off sewer shall be satisfactorily isolated
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the overpumping system shall be provided to the approval of the Engineer.

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1 Interruption of service will not be permitted.

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10.4.4 Pumping Plant

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1 Overpumping shall be carried out using suitable mobile pump sets of adequate capacity and
head to the approval of the Engineer.
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2 The Contractor shall provide sufficient number of standby pumps of adequate capacity.
Where required by the Engineer, a temporary sump shall be provided to prevent surcharging
of upstream sewers.
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3 The pumps shall be controlled by suitable level controls installed to operate at levels to be
approved by the Engineer and shall be capable of dealing with the flow in the sewer and any
material likely to be transported in it without being blocked.
10.4.5 Sewage Flooding
1 Full-time attendance with mobile phone facilities shall be provided by the Contractor at each
pumping location such that in the event of mechanical breakdown, flooding or blockage,
immediate assistance will be summoned.
10.4.6 Overpumping of Flow
1 Pumped sewage flows shall be discharged to a manhole downstream of the sewer length
being cleaned or surveyed. The open end of the pump delivery pipe shall be laid in order to
minimise turbulence of the pumped flow. No sewage shall be dumped onto any surfaces
outside the sewer system.
2 The pump delivery pipe shall be of suitable armoured material which in all locations subject to
traffic flow shall be suitably protected with preformed steel plates bridging the pipe or by other
means approved by the Engineer. Such protection shall be adequate to allow passage of
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vehicular traffic over the pipe.
10.4.7 Temporary Diversion of Flow
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1 Where temporary sewer diversion is required the Contractor shall notify the Engineer
accordingly and submit his proposals for implementation of such diversion.
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2 The Contractor shall obtain all other permissions and approvals from relevant authorities
prior to commencement of such diversion. On completion of temporary diversionary works
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the temporary pipelines shall be removed or be adequately sealed and inlet and outlet
manholes reinstated to their original condition.
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10.4.8 Entrances to Private Properties M
1 The Contractor shall not cause any obstruction to the access of private properties. If the
obstructions are unavoidable, the Contractor shall provide and maintain in good order
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alternative access to the approval of the Engineer.

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10.4.9 Odour and Noise Control During Flow Diversion and Overpumping
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1 The Contractor shall take necessary precautions for controlling odour and noise with
prescribed limits approved by the Engineer and for preventing nuisance and inconvenience to
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the local residents and the public during the flow diversion and overpumping operations.
2 The Contractor shall include in his method statement, the measures to be taken for noise
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and odour control.

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3 The Contractor shall provide special measures to prevent the odour release to the approval
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of the Engineer.
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4 The Contractor shall install temporary chemical dosing system to contain the odour release if
other measures fail.
5 For odour control, the measurement of hydrogen sulphide shall not be more than 1 ppm
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measured at a distance of 1m from the point of discharge to the adjacent property.
CONTRACTOR’S QUALITY CONTROL PROCEDURE

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10.5
1 The Contractor shall operate a quality control system, to be approved by the Engineer, which
will effectively gauge the accuracy and consistency of the CCTV survey report produced by
the operator from the monitor picture.
2 The system shall be such that the accuracy of reporting should be a function particularly of:
(a) The number of faults not recorded (omissions).

(b) The correctness of the coding and classification of each fault recorded.
3 The minimum levels of accuracy to be attained shall be as follows:

(a) Header accuracy 95%

(b) Detail accuracy 85%
(c) Lowest acceptable tolerance 75%
4 The Engineer shall be entitled in accordance with Section 1 Part 8 and this section to audit
periodically the control system and be present when assessments are being computed.
5 When requested by the Engineer, the Contractor shall forward to the Engineer sufficient
details and information for this audit assessment.
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6 Should any report fail to achieve the specified percentages for a particular pipe length, the
Engineer shall require the Contractor to re-code and re-submit the report. If the accuracy
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check fails, the Contractor shall repeat the full quality control check on 10 surveys, 5 surveys
either side of the survey which has failed. If any further failures are found to be outside the
tolerances laid down above within these additional checks, the process will be repeated until
an acceptable standard is reached. Any reports that have failed will be re-coded by another
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qualified surveyor and submitted to the Engineer to replace those in his possession.
7 Quality selection is achieved by using two parameters:
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(a) Population - the anticipated number of surveys carried out by one surveyor over a
period of time (normally I year).
(b)
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Sample size - the number of surveys required to be checked to satisfy the quality
control validity.
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8 The sample surveys for quality control are to be selected by the use of computer generated
random numbers (ERNI) or other such equivalent method and shall be 5% of the total
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population. Each surveyor shall have a different set of random numbers, which are sorted
into chronological order, and are renewed once the population size has been reached. The
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random numbers shall not be disclosed to the surveyor until they have been used up.
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9 On site the surveyor logs certain information on the surveys being carried out and in the order
in which they are surveyed.
The “in-office” staff then count, through the surveys that have taken place and copy those
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reports that coincide with the random numbers.
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11 Copy of the relevant section of the recording shall also be made available.
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12 Information on the recording and its contents are entered on a survey selection log.
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13 Header information - All header information shall be checked to ensure that left and right
justified entries are correctly entered, alpha or numeric symbols are correctly used and all
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compulsory boxes filled in. The percentage of accurate entries shall be ascertained and any
that fall below the value specified shall be rejected. All decimal percentage points shall be
rounded down to the nearest whole number.
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14 Detail information - Each error/omission is treated on an equal basis whether or not it is a

minor or major error or omission. During the checking each error/omission is highlighted on
the report from which the following totals are calculated for each survey report:
(a) The number of actual entries that should have been made.
(b) The number of actual errors/omissions made.
15 These totals are entered on the right of the survey report being checked. Individual column
totals are also calculated and entered on to the survey accuracy log.
16 The accuracy of each survey is arrived at by taking the number of actual errors/omissions
away from the number of actual entries that should have been made and dividing the result
by the number of actual entries that should have been made and multiplying by 100 to create
a percentage.
17 This percentage is entered on the survey detail rating form.
18 The ongoing accuracy of the surveyor (the “confidence level”) is calculated by taking the
mean of 5 percentage results (each 5 representing one control unit).
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19 Both the individual survey percentages and the mean results are entered onto the surveyor’s
accuracy graph which has two boundaries:
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(a) Specified mean - the level of accuracy expected.
(b) Specified tolerance - the level to which the accuracy can fall before specific action is
taken.
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20 Any surveyor whose quality control results fall below the specified mean on more than 2
occasions or the specified tolerance at any time shall be deemed to have failed his quality
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control criteria and shall be invalidated from acting as a team leader on this Contract until he
has attended and passed an approved course for pipe condition classification.
END OF PART
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Part 11: Sewer Rehabilitation
11 SEWER REHABILITATION ........................................................................... 3
11.1 GENERAL ...................................................................................................... 3

11.1.1 Scope 3
11.1.2 References 3
11.1.3 Definitions 5
11.1.4 Submittals 6
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11.1.6 Warranty 9
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11.2 GENERAL REQUIREMENTS ........................................................................ 9
11.2.1 Work Programme Review, Cleaning, Inspection 9
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11.2.2 Safety 9
11.2.3 Preparation for Installation of Linings 9
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11.2.5 Annulus Grout 11
11.3
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SEALING OF PIPES AND MANHOLES ...................................................... 11
11.3.1 Scope 11
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11.3.2 Sealing Compounds 11

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11.3.3 Joint Sealing of Pipes 12

11.3.4 Sealing of Manholes 14
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11.4 SLIPLINING OF SEWERS .......................................................................... 15

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11.4.1 General 15
11.4.2 Materials 15
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11.4.3 Installation of Sliplining 16

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11.5 DEFORMED PIPE LINER INSTALLATION ................................................. 18

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11.5.1 Scope 18
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11.5.2 Materials 18
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11.6 CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD) ......... 20

11.6.1 Scope 20
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11.6.2 Materials 21
11.6.3 Installation of Cured-In-Place Liner 22
11.7 SPIRAL WOUND PROFILE LINER ............................................................. 23
11.7.1 Scope 23
11.7.2 Materials 23
11.7.3 Installation of Spiral Wound Profile Liner 25
11.8 PIPE CRACKING OR BURSTING ............................................................... 26

11.8.1 Scope 26
11.8.2 General 26
11.8.3 Materials 26
11.8.4 Installation Equipment 27
11.9 INSPECTION AND TESTING OF PIPE LINES AFTER
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REHABILITATION ....................................................................................... 29
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11.10 MANHOLE REHABILITATION..................................................................... 30
11.10.1 Scope 30
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11.10.2 General 30
11.10.3 Materials 30
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11.10.4 Rehabilitation of Manhole Walls and Bases 31
11.10.5 Rehabilitation of Manhole Shafts and Slabs 31
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11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or
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Replacement 31
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11.11 MANHOLE LINING ...................................................................................... 32

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11.11.1 Scope 32
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11.11.2 Materials 32
11.11.3 Installation of Lining 32
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11 SEWER REHABILITATION
11.1 GENERAL
11.1.1 Scope
1 This Part includes the specifications for all work necessary to rehabilitate sewers, manholes
and chambers including, but not limited to:
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(a) sealing of sewers and manholes
(b) manhole rehabilitation
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(c) manhole lining
(d) sliplining of sewers
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(e) deformed pipe lining
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(f) cured-in-place pipe (inversion method)
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(g) spiral wound profile liner
(h) pipe cracking or bursting.
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This Section
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Part 1 General
Part 2 Earthworks
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Part 4 Pipeline Installation

Part 6 Metal Works
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Part 7 Miscellaneous GRP Works

Part 8 Painting and Protective Coatings
Part 10 Sewer Cleaning and Inspection Survey
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11.1.2 References
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ASTM C923 M ............Specification for Resilient Connectors Between Reinforced Concrete

Manhole Structures Pipes and Laterals [Metric]
ASTM D543 ................Resistance of Plastics to Chemical Reagents
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ASTM D618 ................Methods of Conditioning Plastics and Electrical Insulating Materials

ASTM D638 ................Standard test method for tensile properties of plastics.
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ASTM D746 ................Standard test method for brittleness temperature of plastics and
elastomers by impact.
ASTM D790 ................Standard Test Methods for Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials
ASTM D883 ................Definition of Terms Relating to Plastics
ASTM D991 ................Standard test method for rubber property-volume resistivity of
electrically conductive and antistatic products.
ASTM D1238 ..............Standard test method for melt flow rates of thermoplastics by extrusion
plastometer.
ASTM D1248 ..............Specification for Polyethylene Plastics Moulding and Extrusion

Materials
ASTM D1505 .............Standard test method for density of plastics by the density gradient
technique.
ASTM D1525 ..............Standard test method for Vicat softening temperature of plastics.
ASTM D1600 ..............Abbreviations of Terms Relating to Plastic Pipes
ASTM D1693 ..............Test for Environmental Stress-Cracking of Ethylene Plastics
ASTM D1784 ..............Specification for Rigid PVC Compounds and Chlorinated PVC (CPVC)
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Compounds
ASTM D2122 ..............Method for Determining Dimensions of Thermosetting Pipe and
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Fittings by Acetone Immersion
ASTM D2152 ..............Test Method for Degree of Fusion of Extruded PVC Pipe and Moulded
Fittings by Acetone Immersion
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ASTM D2240 ..............Standard test method for rubber property-Durometer hardness.
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ASTM D2412 ..............Test Method for Determination of External Loading Characteristics of
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Plastic Pipe by Parallel-Plate Loading
ASTM D2444 ..............Test Method for Impact Resistance of Thermoplastic Pipe and Fittings
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by means of a Tup (Falling Weight)
ASTM D2657 ..............Practice for Heat-Joining Polyolefin Pipe and Fittings
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ASTM D2837 ..............Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials
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ASTM D3035 ..............Specification for Polyethylene (PE) Plastics Pipe (SDR-PR) Based on
Controlled Outside Diameter
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ASTM D3350 ..............Specification for Polyethylene Plastics Pipe and Fittings Materials
ASTM D3753 ..............Specification for Glass-Fiber-Reinforced Polyester Manholes
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ASTM D4703 ..............Standard practice for compression moulding thermoplastic materials

into test specimens, plaques or sheets.
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ASTM F412 ................Definitions of Terms Relating to Plastic Piping Systems

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ASTM F477 ................Specification for Elastomeric Seals for Joining Plastic Pipe
ASTM F585 ................Practice for Insertion of Flexible Polyethylene Pipe into Existing
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Sewers
ASTM F714 ................Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on
Outside Diameter
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ASTM F1216 ..............Rehabilitation of Existing Pipelines and Conduits by the Inversion and
Curing of a Resin-Impregnated Tube
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ASTM F1248 ..............Standard test method for determination of environmental stress crack
resistance (ESCR)of polyethylene pipe.
ASTM F1533 ..............Standard specification for polyethylene (PE) pipe
ASTM F1606 ..............Standard practice for rehabilitation of existing sewers and conduits
with deformed polyethylene (PE) liner.
ASTM F1697 ..............Standard specification for poly (vinyl chloride) (PVC) profile strip for
machine spiral-wound liner pipe rehabilitation of existing sewers and
conduits
ASTM F1698 ..............Installation of Poly (Vinyl Chloride) (PVC) Profile Strip Liner and
Cementitious Grout of Rehabilitation of Existing Man-Entry Sewers
and Conduits
ASTM F1741 ..............Standard practice for installation of machine spiral wound poly (vinyl
chloride) (PVC) liner pipe for rehabilitation of existing sewers and
conduits.
ASTM F794 ................PVC Large Diameter Ribbed Gravity Sewer Pipe and Fittings based on
Controlled Inside Diameter
BS 2494......................Materials for elastomeric seals for joints in pipework and pipelines
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BS 4346......................Joints and fittings with unplasticized PVC pressure pipes
BS 5556......................Specifications for general requirements for dimensions and pressure
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ratings for pipes of thermoplastic materials
BS 5955......................Code of practice for plastic pipe work
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BS 8010......................Pipelines
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BS EN 752..................Sewerage
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BS EN 1401................Plastic piping systems
BS EN 13244..............Polyethylene pipes (type 50) in metric diameter for general purposes
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BS EN 1852-1 ............Plastic piping system for non-pressure underground drainage and
sewerage polypropylene (PP)
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CP 312, ......................Plastic pipe work

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ISO 161 ......................Thermoplastic Pipes for the Transport of Fluids Nominal Outside
Diameters and Nominal Pressures
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ISO 9000 ....................Quality Systems

ISO 9967 ....................Method for Determination of Long Term Ring Stiffness
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WRc ...........................Sewer Rehabilitation Manual

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11.1.3 Definitions
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1 The following terms have the meanings hereby assigned to them except where the Contract
clearly renders these meanings inapplicable:
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(a) Sliplining: insertion of a new liner pipe into an existing pipeline of larger diameter
followed by grouting of the annulus.
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(b) Cured-in-place, inversion, in-situ or soft lining: the creation of a new pipe within an
existing pipeline by insertion of a resin impregrated polyester felt liner by inversion
under pressure lining inversion under pressure, the liner then being cured in-situ.
(c) Spiral wound profile lining: insertion of helically wound, profile walled thermoplastic
sections to form a liner, followed by grouting of the annulus.
(d) Deformed pipe lining: a continuous deformed pipe which reverts to its predeformed
shape after installation.
(e) Pipe cracking or bursting: replacement of an existing pipeline between manholes or

inspection chambers or a combination thereof with a new pipe of equivalent or
greater size whereby the new pipe is inserted behind the pipe breaking machine as
fragments of the existing pipe are displaced to the sides.
(f) Length of sewer: length of sewer pipe between two consecutive manholes or
inspection chambers.
(g) Service connection: the connection of the property sewer with the main sewer pipeline.
11.1.4 Submittals
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1 The Contractor shall submit complete data and details of sewer rehabilitation for the
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Engineer’s approval as follows:
(a) name and experience of specialist subcontractor
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(b) a programme of work, detailed method statement, and schedule of plant to be used in
the Works, detailing the working practices, and specialist equipment.
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(c) proposed method of overpumping or flow diversion as applicable to undertake sewer
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rehabilitation.
(d) specific data for proposed materials and equipment for the Engineer’s approval 14
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days prior to commencement of any sewer rehabilitation works as follows:
(i) test certificates and technical literature to show that the sealants, liners, and
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lining systems materials proposed meet the requirements stated in the

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specifications
(ii) original catalogues specific to the requirement for all proposed equipment. All
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equipment shall be suitable and made of such materials to withstand the

prevailing climatic conditions of Qatar and the corrosive environment.
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(e) Specific data to be submitted while carrying out and at the completion of the work:
(i) records of sealing of sewers in each length of sewer, including joint sealing
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verification results
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(ii) CCTV video tapes, pictures in digital format (TIFF) and site coding sheets
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prepared in accordance with Part 10 of this Section showing the initial condition
and the completed work including the restored condition.
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(f) The Contractor shall submit to the Engineer following data for 15 sewer rehabilitation
projects carried out by the proposed subcontractor during the last five years:
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(i) project location

(ii) name and address of client
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(iii) start and completion dates

(iv) cost of the works
(v) length, diameter and material of pre-rehabilitated sewers
(vi) length, diameter and liner material for each type of rehabilitation system
(vii) reference letter from the client or the engineer.
2 The Contractor shall submit the following data to supplement (d) of this sub-clause:
(a) Sewer Liner

(i) Manufacturers name.
(ii) Suppliers name.
(iii) Installers name (Subcontractor)
(iv) Product name (if applicable).
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(v) Product description.
(vi) Manufacturers technical data.
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(vii) Test results or certificates.
(viii) Checked and approved liner pipe thickness design and stiffness calculations.
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(ix) Storage instructions.
(x) Installation instructions.
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(xi) Installation records in the same project area
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(xii) Proposed grout mixture where applicable.
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(b) Manhole and joint sealing materials and manhole rehabilitation materials
(i) Manufacturers name.
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(ii) Suppliers name.

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(iii) Installer name (Subcontractor)

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(iv) Product name (if applicable).

(v) Product description.
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(vi) Manufacturers technical data.

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(vii) Test results or certificates.

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(viii) Storage instructions.

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(ix) Application instructions.
3 The Contractor shall submit method statements to the Engineer for approval 4 weeks in
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advance of commencing the site activity. These shall comprise but not necessarily be limited
to:
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(a) Sewage bypass pumping and/or diversion plan which shall include an emergency
response plan to be followed in the event of a failure of the bypass pumping and/or
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diversion plan.
(b) Detailed construction plan including:
(i) Equipment set-up and locations of proposed access points.
(ii) Anticipated cut off periods for services.
(iii) Procedures for verification of active service connections.
(iv) Procedures for notifying affected residences and businesses.
(v) Procedures for complying with traffic control.
(vi) Procedures to be adopted to obtain permits to work from the Drainage Affairs.
(vii) Safety procedures in particular working with scaffolding, entering confined

spaces and operations with hot media.
(viii) Sewer cleaning procedures.
(ix) Liner installation procedures.
(x) Procedures for sealing annular space between liner pipe and host pipe where
applicable.
(xi) Methods of sealing any annular space between liner pipe and host pipe at
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manholes.
(xii) Procedures for manhole liner-pipe liner joint sealing.
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(xiii) Procedures for manhole rehabilitation.
(xiv) Procedure for any required modifications (temporary or permanent) to existing
manholes (such as widening of access opening, removal of cover slabs,
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removal of intermediate landings, ladders, removal of manholes benching etc).
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4 The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity. These shall comprise but not necessarily be limited to:
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(a) Liner insertion locations. M
(b) Sewage bypass pumping and/or diversion locations.
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(c) Liner end sealing at manholes and GRP lamination to manhole wall and benching
liners.
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(d) Any required modification to existing manholes.

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5 Representative samples, as agreed with the Engineer, must be submitted for at least the
following items before work commences.
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(a) Proposed liner system.

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(b) Liner to host pipe sealing materials.

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(c) Manhole rehabilitation materials.

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(d) Manhole liner to pipe liner sealing materials.

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1 The system shall be design to comply with the appropriate provisions of BS 2782, BS 3412,
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BS 5556, BS EN 752 and BS 8010.
2 The Contractor shall employ approved prequalified specialist subcontractors designated in

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the Project Specification.
3 The specialist subcontractor shall conduct this work in accordance with the quality
management procedures conforming to ISO 9000.
4 Key operators employed of the subcontractor shall be competent in the relevant sewer
rehabilitation methods and techniques.
11.1.6 Warranty
1 The Contractor shall provide the Engineer with a seven year unconditional warranty against
failure of all GRP manhole linings whether caused by defective materials or workmanship.
The warranty shall be valid from the date of completion of the installation and submitted to
the Engineer as a precondition to the issuance of the Certificate of Completion.
11.2 GENERAL REQUIREMENTS
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11.2.1 Work Programme Review, Cleaning, Inspection
1 When designated in the Project Specification, the Contractor shall allow in his programme of
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work for the requirement that he shall work at many locations at any one time. However, at
least one team shall be fully engaged on each length of sewer, and shall finish all
rehabilitation works required on that length of sewer including manholes and chambers
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before beginning work on a new length of sewer.
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2 The Contractor shall provide methods statements for each of the rehabilitation methods and
systems he proposes to use for each of the functional requirements designated in the Project
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Specification.
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3 As cleaning and inspection work proceeds, the Contractor shall submit weekly sewer and
manhole condition reports to the Engineer. In the reports, the Contractor shall include his
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confirmation that his proposed method of rehabilitation meets the required performance
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criteria. Should the originally proposed method not meets the performance requirements for
lengths of sewer, or manholes, the Contractor shall submit his proposals to meet the
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performance requirements for such lengths of sewers or manholes to the Engineer for
approval.
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4 The Engineer and the Contractor shall agree on the locations and systems to be used for
rehabilitation if necessary, and if necessary the Contractor shall review and revise his
programme of work and submit to the Engineer for approval. The Engineer’s approval shall
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not relieve the Contractor of his obligations under the Contract.

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5 Sewer cleaning, inspection and overpumping work shall be satisfactorily completed before
undertaking sewer rehabilitation.
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11.2.2 Safety
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1 The Contractor shall carry out all operations in accordance with the safety requirements
specified in Section 1 and Part 10 of this Section.
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11.2.3 Preparation for Installation of Linings
1 The following installation procedures shall be adhered to unless approved otherwise by the
Engineer:
(a) before installing lining in sewers the Contractor shall ensure that the sewers are clean
of debris in accordance with Part 10 of this Section. Sewers shall also be gauged to
ensure that they can accommodate the liners.
(b) the Contractor shall inspect by CCTV the section or sections to be lined and shall
record salient features including any obstructions and service connections, in
accordance with Part 10 of this Section.
(c) the Contractor shall overpump the sewage flow around the section or sections of the
pipeline that are to be lined. The overpumping shall be carried at in accordance with
Part 10 of this Section. Leaks in the pipes due to groundwater infiltration shall be
stopped by grouting or other appropriate methods approved by the Engineer.
(d) the Contractor shall clear the pipeline of obstructions, solids, dropped joints, or tree
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roots or collapsed pipe that will prevent the insertion of the liner. Where inspection or
gauging reveals an obstruction that is not at the location of the entry shaft, the
Contractor shall remove the obstruction by means of a cutting machine inserted into
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the sewer line. Where this is not possible, the Contractor shall make an excavation to
expose and remove or repair the obstruction as directed by the Engineer.
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(e) a temporary tie-in shall be made between the relined section and the existing system
and the bypass plug removed at the end of each working day.
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(f) Prior to dispatch of any product and/or material from source the Contractor shall notify
the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect
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and test the product and/or material prior to delivery.
(g)
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To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours notice of carrying out the following activities on site.
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(i) Sewer cleaning.
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(ii) CCTV survey.

(iii) Sewage bypass pumping and/or diversion.
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(iv) Liner installation.

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(v) Manhole rehabilitation.

(h) No lining work shall be permitted until the prepared sewer has been inspected and
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(i) Where it is necessary to carry out any modification to existing manholes to enable
manhole and/or sewer cleansing, CCTV survey or sewer rehabilitation, the Contractor
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shall carry out any such modification to the Engineer’s approval. Following completion
of the works in a manhole, the Contractor shall return the manhole to its original or
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better condition to the approval of the Engineer including reinstatement to surfaces

disturbed as a result of manhole modification/sewer rehabilitation. Modification to
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manhole may include removal of manhole cover slab, intermediate landing slabs,
platforms and manhole benching. Removal of intermediate landing slabs/platforms
may be considered as permanent (i.e. may not necessarily be reinstated) provided the
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GRP wall liner is extended to cover the exposed area due to slab removal and welded
to the existing liner, and the GRP ladder is adjusted and re-installed as a continuous
ladder throughout the manhole height.
(j) Unless specifically itemised and listed in the BOQ, modifications to manholes which
may be necessary to carry out the sewer rehabilitation and associated works shall be
deemed to be included in the sewer rehabilitation rates.
1 Delivery, storage and handling of products and materials shall be in accordance with the
manufacturers’ recommendations and the following provisions.
(a) Delivery storage and handling shall at all times be performed in a manner to avoid
product damage.
(b) The liner shall not come in contact with any sharp projections that may cause damage
during transportation loading and unloading. Cover liner during transportation.
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(c) Store materials on a flat level area and raised above the ground on timber bearers.
(d) Store materials under opaque cover and out of direct sunlight at all times. Maintain a
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free flow of air around materials at all times.
(e) The Contractor shall visually inspect all products upon delivery to site and report any
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damage to the Engineer.
2 Any products damaged during delivery, storage and handling shall be marked by the
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Contractor and set aside.
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3 Proposals for repair of any damaged products shall be submitted in writing to the Engineer
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for approval.
4 Any damaged products deemed unsuitable for repair by the Engineer shall be removed from
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site and replaced.

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11.2.5 Annulus Grout

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1 Low strength grout filling the annular space between the host pipe and the liner (where
applicable) shall be a cementitious mixture incorporating suitable admixtures as approved by
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2
the Engineer and shall have a minimum compressive strength of 12N/mm .
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2 Generally, the equipment shall be capable of performing the specified operations in lines
where flows do not exceed the maximum line flows for joint testing/sealing.
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11.3 SEALING OF PIPES AND MANHOLES

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11.3.1 Scope
1 Complete or an initial step of rehabilitation by the remote sealing of sewer pipe joints using a
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sealing packer. The materials specified herein shall also be applicable in sealing of man-
access sewers and manholes.
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11.3.2 Sealing Compounds
1 The sealing material shall comply with BS 2494 and shall perform effectively in the intended
application and under expected field conditions.
2 Mixing and handling of sealing materials shall be in accordance with the manufacturer’s
recommendations.
3 Chemical sealing compounds shall have the following properties and characteristics:
(a) while being injected, the chemical sealant shall be able to react/perform in the
presence of either, or both, surface water or groundwater, if present
(b) the cured material shall withstand submergence in either, or any combination of,
surface water, groundwater, sea water or sewage without degradation
(c) the resultant sealant formation shall prevent the passage of water through the sewer
pipe joint
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(d) the sealant material, after curing, shall be flexible
(e) in place, the formed sealant shall be able to withstand wet/dry cycles without
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adversely affecting the seal
(f) the formed sealant shall be non-biodegradable
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(g) the cured sealant shall be chemically stable and resistant to the chemical constituents
sewage and the sewer environment
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(h) packaging of component materials shall
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(i) be compatible with site storage and handling requirements
(ii) ensure worker safety
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(iii) cause minimal spillage during handling
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(i) mixing of the component materials shall be compatible with field operations
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(j) cleanup shall be effected without inordinate use of flammable or hazardous chemicals
(k) residual sealing materials shall be removed from the sewer to prevent any blockage of
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the sewage flow.

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4 Chemical resin for sealing pipe joints and manholes shall be a hydrophilic polyurethane
compound suitable for injection.
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5 The material must be “salt-water” grade, able to react with saline ground water to form a
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flexible seal.
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11.3.3 Joint Sealing of Pipes

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1 Joints shall be sealed using the internal joint sealing method. Where bell cracks or chips are
evident from pipe section offset, sealing shall be undertaken where the offset is small enough
to allow proper seating of the sealing packer on both sides of the joint to be sealed.
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Longitudinally cracked or broken pipe shall be replaced.

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2 The sealing equipment shall comprise a CCTV survey system, chemical sealant containers,
pumps, regulators, injection sealing packers, hoses, valves and all other necessary
apparatus and tools required for sealing sewers of the various diameters. The packer shall
be cylindrical and shall be so sized and have cables attached at each end to enable it to be
pulled freely through the pipeline. The packer device shall be constructed in a manner to
allow an amount of sewage to flow as designated in the Project Specification.
3 Joint shall be sealed by injecting chemical sealing compound into or through faulty joints
using a system of pumps, hoses, and sealing packers. Jetting or driving pipes from the
surface that could damage the pipelines or impair their structural integrity will not be
permitted. Uncovering the pipe by excavation of pavement and soil will not be allowed. The
packer shall be positioned over the faulty joint by means of a measuring device and the
CCTV camera in the pipeline. The Contractor shall ensure that the packer is accurately
positioned over the joint. The packer ends shall be expanded using controlled pressure. The
expanded ends shall seal against the inside periphery of the pipe to form a void area at the
faulty joint which shall be completely isolated from the remainder of the pipeline. Sealant
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compound shall be pumped into the isolated area through the hose system at controlled
pressures in excess of groundwater pressure, if any.
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4 Upon completing sealing of each joint, the packer shall be completely deflated then reinflated
and the joint retested. Should the void pressure meter not read zero after deflation, the
Contractor shall clean his equipment of residual grout material or make the necessary
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equipment repairs/adjustments to produce accurate void pressure readings. Joints that fail to
meet the specified test criteria shall be resealed and retested until the test criteria can be
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met.
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5 Residual sealing materials protruding into the pipe shall be removed. The sealed joints shall
be left flush with the pipe surface. Excessive residual sealing materials which accumulate in
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the pipeline shall be removed.
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6 Records shall be kept of joints sealing performed in each length of sewer to identify the
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length of sewer in which joints were, the location of each joint sealed, and the joint sealing
verification test results.
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7 Not more than one month before the expiration of the Period of Maintenance and as a
precondition to the Engineer’s issuance of the Maintenance Certificate for the Contract,
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sewers shall be retested as follows:
(a) an initial retest area consisting of specific lengths of sewers will be selected by the
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Engineer. Length of sewers to be retested shall be randomly selected throughout the

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project area and shall be representative of the majority of the sealing work originally
performed. The initial retest area shall consist of at least 5 %, but not exceed 10 %, of
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the length contained in the Contract

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(b) within the initial retest area, the Contractor shall retest all previously sealed joints as
specified. Any joints failing the retest shall be resealed at no extra cost to the Employer
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(c) if the failure rate of the joints exceeds 5 % of the retested joints, an additional retest
area of equivalent size will be selected by the Engineer and all previously sealed
joints shall be retested. The additional testing and sealing, where necessary, shall
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continue until a failure rate of less than 5 % is achieved

(d) additional testing or sealing required beyond the initial retest area shall be
accomplished at the Contractor’s expense. The Contractor shall provide adequate
number of crews at Site so that the retesting will proceed at a rapid rate.
8 The pumping unit, metering equipment and the packer device shall be designed so that
proportions and quantities of materials can be regulated in accordance with the type and size
of the leak being sealed.
11.3.4 Sealing of Manholes
1 During cleaning and inspection work the condition of manholes shall be observed and their
structural soundness shall be evaluated by the Contractor and reported in the cleaning and
inspection reports. Sealing work shall only be carried out on manholes which the Engineer
considers structurally sound and which experience extraneous water leakage.
2 Cracks and openings to be sealed shall be marked out in detail on the concrete elements by
the Contractor and agreed with the Engineer before proceeding with sealing operations.
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3 Sealing equipment shall consist of chemical sealant containers, pumps, regulators, injection
packers, hoses, valves, and all other necessary apparatus and tools. The chemical injection
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pumps shall be equipped with pressure meters for monitoring pressure during the injection of
the chemical sealants. Where necessary, fluid bypass lines equipped with pressure-
regulated bypass valves shall be incorporated into the pumping system.
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4 Structural cracks shall be repaired out as follows:
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(a) holes shall be carefully drilled close to the damaged section from within the manhole
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and shall extend through the entire manhole wall
(b) if leakage is occurring through cracks due to high groundwater table, fewer holes shall
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be drilled provided all leakage is stopped from these holes. A watertight seal between
the holes and the injection device shall be provided. Hoses, shall be attached to the
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injection device from an injection pump. Chemical sealing materials shall then be
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pumped through the hose until material refusal is recorded on the pressure gauge
mounted on the pumping unit or a predetermined quantity of sealant has been injected
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(c) care shall be exercised during the pumping operation to ensure that excessive
pressures do not develop and causing damage to the manhole structure
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(d) upon completion of the injection, the packers shall be removed and the remaining
holes filled with mortar and trowelled flush with the surface of the manhole walls or
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other surfaces
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(e) the mortar used shall be of the quick-setting type with non-shrinking characteristics
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(f) any GRP internal lining which has been disturbed shall be repaired in accordance with
Part 7 of this Section.
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5 Not more than one month before the expiration of the Period of Maintenance and as a
precondition to the Engineer’s issuance of the Maintenance Certificate for the Contract,
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manholes shall be visually inspected by the Contractor in the presence of the Engineer.
Sealing work that has become defective shall be repaired at no additional cost to the
Employer.
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6 All manhole sealing shall be done during high groundwater conditions, unless the points of
leakage have been previously identified.
11.4 SLIPLINING OF SEWERS
11.4.1 General
1 The scope of work consists of rehabilitating sewers by the insertion of liner pipe into existing
sewers. The finished liner shall extend the full distance detailed in the project specific
documentation, which may be for localised repair, or extend the full sewer length. In either
case the lining shall be completely sealed and watertight.
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2 Procedures set out in ASTM F 585 shall be followed, except as otherwise specified in this
Part.
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3 The Contractor is not constrained on the type of lining method he puts forward, but the
Contractor will have to demonstrate, through previous project documentation, that the
proposed method has a proven track record and that it is fully applicable to the conditions to
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be found in the Gulf region.
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4 The Contractor shall design the liner to support all combinations of imposed loads including
earth, traffic, hydrostatic etc and have a minimum service life of 50 years. For the purpose of
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calculations, it shall be assumed the ground water table is at ground level. Host pipes shall
be considered to be fully deteriorated. The liner shall have a minimum allowable long term
2
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stiffness of 2500N/m and be designed to have a factor of safety of 2.
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5 The normal requirement will be that the liner shall provide the least possible thickness or
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decrease in diameter to meet the requirements of this section and consequently it is

preferable to be of the close fit type.
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6 Liner shall be of a light colour to enhance Closed Circuit Television (CCTV) clarity for
inspection purposes.
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7 Leak repair shall be carried out when required to create an environment to enable the
rehabilitation works to be executed successfully. If the rehabilitation method adopted can be
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successfully implemented under wet conditions, the Contractor is not obliged to repair the
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leaks.
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8 The finished liner shall be continuous over the entire length of an insertion run between two
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manholes or access points and shall be free from visual defects.
9 The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to
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manhole liner using a material that is compatible with the liner.
11.4.2 Materials
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1 The sewer liner pipe and fittings shall be manufactured from a polyethylene compound
conforming to ASTM D1248 and meeting the requirements for Type II or III, Class B or C,
Grades P23 or P34, Category 5. Pipe made from this compound shall have a minimum long-
term hydrostatic strength rating of 8.6 MPa in accordance with ASTM D2837. When the
environmental stress crack resistance (ESCR) of the compound is measured in accordance
with ASTM D1693, Condition C, the compound shall withstand not less than 192h in 100 %
solution Igepal CO-630 at 38 C before reaching a 20 % failure point (F20).
2 The standard dimension ration (SDR), defined as the specified outside diameter (OD) divided
by the minimum wall thickness, shall be demonstrated by calculation to be sufficient to
support the worst combination of internal and external loads. The wall thickness tolerance
shall be within plus 12 %.
3 Liner pipe shall be provided with joints designed so that neither the outside diameter of the
pipe is increased nor the internal diameter of the pipe is decreased at the joint.
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4 Liner pipes shall be suitable for use in ambient air temperatures up to 55 C and with sewage
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up to 45 C.
11.4.3 Installation of Sliplining
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1 Where excavations for insertion of liner are made, the Contractor shall locate the excavations
on the basis of the location of the sewers to be sliplined, pulling distances, and traffic
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conditions subject to Engineer’s approval. Excavation locations shall be such as to minimise
traffic disruption, and the number of excavations reduced by inserting the pipe in both
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directions from a single opening. Insertion shafts shall be designed to avoid imposing a
bending radius of less than 35 times the outside diameter of the liner. Insertion shafts shall
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be sloped gradually from the ground surface to the soffit of the sewer. The Contractor shall
provide sufficient sheeting and bracing to the excavation as required. The soffit of the
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existing sewer shall be exposed and the crown of the pipe shall be removed as necessary for
insertion of the liner. Care shall be taken not to disturb the bottom portion of the existing
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pipe.
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2 Jointing shall be by thermal butt-fusion welding in accordance with the manufacturer’s

recommendations. All fusion jointing shall be carried out by trained personnel with equipment
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designed for butt-fusion welding of thermoplastic pipe.

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3 Sections of liner shall be jointed above ground either at the Site or at a remote location.
4 Where the insertion shaft is not at a manhole the jointing shall be accomplished using a
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stainless steel full-encirclement clamp. If such jointing cannot be achieved, then a new
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manhole shall be constructed. Recommended minimum lengths of clamps to afford adequate

pullout protection are given in Table 11.1.
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Table 11.1
Minimum Length of Clamps
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OD of Liner Pipe Minimum Length of Clamp

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(mm) (mm)
90 190
115 250
135 250
170 380
180 380
220 380
270 500
OD of Liner Pipe Minimum Length of Clamp
325 500
340 500
405 760
455 760
475 760
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560 760
661 760
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5 Alternative pipe jointing methods shall be subject to the approval of the Engineer.
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6 The liner shall be inserted with a power winch and steel cable connected to the end of the
liner using of an appropriate pulling head. Where necessary a second pulling head may be
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attached to the other end of the liner for attachment of a tag line to pull the liner back out of
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the sewer.
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Pulling shall be continued form start to completion without interruption, and precautions shall
be taken during insertion to protect the liner pipe so that any ragged edges of a broken sewer
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pipe will not score the outside of the liner.
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8 The manufacturer’s recommendations regarding relaxation of the liner shall be followed

before sealing the annular space between the liner and existing sewer pipe. The annular
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space between the polyethylene liner and the existing sewer shall be sealed using a method
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9 Where an existing manhole is used as an entrance shaft the manhole shall be reinstated to
good condition or it shall be replaced with a new manhole in accordance with Part 4 of this
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Section.
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10 Foam sealant shall not protrude into the manhole and the sealant shall be finished over with
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a quick-setting, non-shrinking type of cement grout. Finishing inside the manhole shall be
accomplished using a quick-setting cement type grout to raise the manhole trough to the
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invert of the liner pipe and reform the manhole benching as required. Exposed cement type
grout surfaces shall be protected against corrosion by lining with GRP in accordance with
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Clause 4.4.1 of this Section.
11 Precautions shall be taken to prevent collapsing of the liner owing to excessive grouting
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pressure.
12 The liner shall be secured in the upstream manhole. Each existing service connection shall
be excavated and reconnected to the new liner pipe using either polyethylene heat fusion
saddles or strap-on saddles as conditions require. A neoprene gasket shall be inserted
between the liner and the strap-on saddle. Saddles shall be secured to the liner pipe using
stainless steel bands. Connections of saddle fittings to existing service connections shall be
made using elastomeric boots, full-encirclement clamps, or other methods approved by the
Engineer.
13 Before backfilling any existing sewers that had been broken to open, the pipe shall be
repaired and the annular space between the existing sewer and the new liner sealed using
cement or expandable foam to the approval of the Engineer.
14 At locations where the liner pipe has been exposed, the pipe and fittings shall be encased in
Grade 20 SRC concrete.
11.5 DEFORMED PIPE LINER INSTALLATION
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11.5.1 Scope
1 The scope of the work consists of rehabilitating sewers by the insertion of a deformed
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thermoplastic pipe into existing sewers. The deformed pipe on the application of pressure
and temperature or on release of deforming stress induced by swaging reverts to its pre-
deformed shape to form a tight fit inside the host pipe without the formation of an annulus.
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11.5.2 Materials
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1 The HDPE liner material shall be designed for use in gravity sewers and shall be in strict
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conformance with all applicable sections of ASTM F1533.
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2 The liner shall be made from High Density Polyethylene resins complying with ASTM D1248,
Type III, Grade P34 and Cell Classification PE 345434C, D or E per ASTM D3350. The
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Contractor shall submit to the Engineer for approval certified test results from the liner pipe
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manufacturer to verify that the resin material used for extrusions of the liner meets the
specified requirements, including the quality control records during the liner extrusion
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process.
3 At the time of manufacture, each lot of liner shall be inspected for defects with samples being
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taken in accordance with ASTM D4703 and tested in accordance with ASTM D1693, ASTM
D2837 and ASTM F714.
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4 For testing purposes a production lot shall consist of all liner having the same marking
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number. It shall include all items produced during any given work shift and must be identified
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accordingly to differentiate it from previous or following production.
5 Each deformed liner coil in compliance with ASTM F1533 shall be clearly marked by the
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manufacturer with the following information:
(a) ASTM F1533 designation.

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(b) Nominal outside diameter.

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(c) SDR.
(d) Approximate coil length.
(e) Standard material designation code.
(f) Manufacturer’s name.
(g) Manufacturer’s production code from which plant location, machine and date of
manufacture can be identified.
(h) The project or contract number.
6 Liner minimum wall thickness shall be determined by strength and minimum stiffness
requirements.
7 The liner shall be fabricated from materials which will be resistant to internal exposure to
sewage, sewage gases and reagents listed in Table 1 above, when tested in accordance with
the provisions of ASTM D543, to a temperature of 40°C.
8 The HDPE material used in the production of the liner shall meet, or exceed, the physical
properties given in Table 11.5 below.
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Table 11.5
Deformed Pipe Liner Properties
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Property Test Method Value
3
Density ASTM D1505 950kg/m
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Flow rate ASTM D1238 8.0g/10min
2
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Tensile strength @ ultimate ASTM D638 30N/mm
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2
Tensile strength @yield ASTM D638 20N/mm
Ultimate elongation ASTM D638 600%

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2
Flexural modulus ASTM D790 1000N/mm
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Environmental stress crack

resistance
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ASTM D1693 10,000 hrs

F0, hours condition C
ASTM F1248 10,000 hrs
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Compressed ring ESCR F0

0
Brittleness temperature ASTM D746 -117 C
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0
Vicat softening temperature ASTM D1525 125 C
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Hardness, Shore D ASTM D2240 50

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15
Volume resistivity ASTM D991 10 ohm-cm
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0
Thermal expansion 0.20mm/m/ C
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9 At the time of installation the liner shall be homogeneous throughout, uniform in colour, free
of cracks, holes, foreign materials, blisters and deleterious faults.
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11.5.3 Installation
1 The Contractor’s method statement shall be submitted to the Engineer for approval. In the
method statement the Contractor shall describe the means of deforming the liner in-situ and
of providing, maintaining, monitoring, and controlling the reforming environment until the liner
has reverted to its original circular shape and the temperature returns to the normal sewer
ambient temperature.
2 Calculations demonstrating the adequacy of the pulling capacity of the winch shall be
prepared and submitted by the Contractor for the Engineer’s approval.
3 The liner shall be positioned at the upstream manhole without excavation and shall be
winched directly from the coil through the upstream manhole and the host pipe.
4 Due care shall be exercised during winching to avoid damage to manholes and snagging.
Guides or rollers shall be used within the manholes to avoid the risk of snagging.
5 The pulling winch shall be equipped with a tension gauge capable of controlled operation at
variable speed.
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6 The pipe shall be cut flush at manhole inlet and outlet points using a rotary cutter and the
joints sealed.
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7 The Contractor shall adopt working practices for plastic pipes accordance with BS 5955.
8 The Contractor shall obtain detailed installation instructions and procedures from the
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manufacturer for the actual installation of the deformed and reformed system. The
requirements of ASTM F1606 shall also be satisfied.
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9 When the deformed pipe liner is in place it shall be cut and the pipe end closing assembly
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used for heat and pressure control within the liner shall be attached and secured at both pipe
ends. Temperature and pressure measuring instruments shall be attached to both ends of
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the deformed HDPE liner to provide a continuous monitor of the temperature and pressure
being applied to the liner.
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10 Through the use of steam and air pressure the deformed pipe shall be reformed to conform
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to the existing pipe wall.

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11 The reformed HDPE liner shall be cooled in accordance with the manufacturer’
recommendations.
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12 Temperatures and pressures shall be monitored and recorded throughout the installation
process to ensure that each phase of the process is achieved at the manufacturer’s
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recommended temperature and pressure limits

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13 For each length of liner two samples shall be taken at locations determined by the Engineer.
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The sampling method shall include the use of a former to replicate the host pipe. The
samples shall be clearly labelled with date taken and location. The samples shall be tested
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for average inside diameter, average outside diameter and minimum wall thickness in
accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
D2412 and for the properties given in Table 3. The stiffness so measured shall meet, or
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exceed the stiffness requirements determined by calculation for that section of sewer line or
the minimum specified stiffness whichever is greater. Any material may be rejected for failing
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to meet any of the requirements of this specification.
14 The water tightness of the liner shall be gauged throughout the forming process.
11.6 CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD)
11.6.1 Scope
1 The scope of work consists of rehabilitating sewers by the installation of a resin impregnated
flexible felt tube inverted into existing sewers. When cured, the new material shall extend
over the length of the inversion as a continuous, tight-fitting, watertight lining.
11.6.2 Materials
1 The liner material shall be designed for use in gravity sewers and shall be in strict
conformance with all applicable sections of ASTM F1216.
2 The felt liner tube shall be a thermoplastic polyester tube consisting of one or more layers of
flexible needled felt or an equivalent woven and/or non/woven material capable of carrying
resin, and with sufficient needling and crosslapping and strength to withstand the installation
pressures and curing temperatures.
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3 The felt tube shall be compatible with the resin and catalyst systems to be utilised.
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4 The finished liner shall consist of a felt layer (or layers) impregnated with a thermosetting
resin and fabricated to fit tight against the host pipe. An allowance shall be made for
circumferential stretching during installation where applicable.
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5 Each felt liner tube shall be clearly marked by the manufacturer with the following
information:
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(a) Manufacturer’s name.
(b) Manufacturer’s production code from which plant location, machine and date of
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manufacture can be identified.
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(c) The project or contract number.
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6 The lining technique shall comprise using a suitable preliner to prevent loss of resin.
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7 The resin used shall be a general purpose, unsaturated, thermosetting, vinylester resin able
to cure in the presence or absence of water and a catalyst system compatible with the
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insertion process that provides physical properties given in Table 11.6.

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Table 11.6
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Cured in Place Liner Properties

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Property Test Method Value

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2
Flexural strength ASTM D790 31N/mm
2
Short term flexural modulus ASTM D790 1724N/mm
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2
Long term flexural modulus ASTM D790 862N/mm
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2
Tensile strength ASTM D638 21N/mm
8 The installed and cured liner shall be chemically resistant to exposure to sewage and sewage
gases as experienced with the high temperatures in Qatar.
9 At the time of installation the liner shall be free of all visible tears, holes, cuts, foreign
materials and other defects.
10 The liner shall be fabricated to a size that when installed will neatly fit the internal
circumference of the sewer being renovated. Allowance shall be made for circumferential
stretching during insertion. The minimum length shall be that deemed necessary by the
Contractor to effectively span the distance from inlet to outlet of the respective manholes
unless otherwise designated in the contract specification. The Contractor shall verify the
lengths on Site before impregnation. Individual inversion runs may be made over one or
more lengths of sewer as determined on Site by the Contractor and approved by the
Engineer.
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11.6.3 Installation of Cured-In-Place Liner
1 The following installation procedure shall be adhered to unless otherwise proposed in the
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Contractor’s method statement and approved by the Engineer:
(a) the Contractor shall designate a location or locations where the reconstruction tube will
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be vacuum impregnated before installation. The Contractor shall allow the
Engineer to inspect the materials and wet-out procedure. A catalyst system
compatible with the resin and reconstruction tube shall be used
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(b) the Contractor shall provide facilities to control the temperature of the wet-out
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reconstruction tube to prevent premature setting of the resin
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(c) the wet-out reconstruction tube shall be inserted through an existing manhole or
other approved access by means of an inversion process and the application of an
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inversion medium of sufficient pressure and volume sufficient to fully extend it to the
designated or termination point
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(d) the inversion pressure shall be adjusted to be sufficient to cause the

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impregnated tube to invert from manhole to manhole and hold the tube tight to the
pipe wall and to produce dimples at side connections and flared ends at the
manholes. Care shall be taken during the elevated curing temperature so as not to
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overstress the felt fibre

(e) after inversion is complete, the Contractor shall provide a suitable curing
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environment. Monitoring and control equipment shall be provided to permit

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observation and maintenance of the curing environment. Temperature and other

factors of the curing environment shall be those recommended by the resin
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manufacturer
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(f) should excessive infiltration into the sewer be present, a preliner shall be inserted
into the sewer line to prevent washout of the resin.
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2 Initial curing shall be deemed to be completed when inspection of the exposed portions of
cured pipe appear to be hard and sound and the remote temperature sensor indicates that
the temperature is of a magnitude to realise an exotherm. The curing period shall be that
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recommended by the resin manufacturer, as modified for the cured-in-place inversion

process, during which time the Contractor shall maintain the quality of the curing environment
to the levels recommended by the resin manufacturer.
3 The Contractor shall cool the hardened liner to a temperature below 38 C before relieving
the pressure. Cooling may be accomplished by the introduction of cool water into the
inversion standpipe to replace water being drained from a small hole made in the
downstream end. Care shall be taken in the release of the static head so that a vacuum will
not be developed that could damage the newly installed liner.
4 Where the new liner fails to make a tight seal due to broken or misaligned host pipe at the
manhole wall, the Contractor shall apply a seal at that point. The seal shall be of a resin
mixture compatible with the liner and the host pipe.
5 After the new liner has been cured in place, the Contractor shall reconnect existing active
service connections as directed by the Engineer. Unless otherwise designated in the contract
specific documentation, shall be done without excavation. In the case of non -man-entry
pipes from the interior of the system by means of CCTV cameras and a cutting devices that
re-establish the service connection and seal the joint at the point of entry of the service
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connection.
6 The Contractor shall obtain detailed installation instructions and procedures from the
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manufacturer for the actual installation of the cured in place liner system. The requirements
of ASTM F1216 shall also be satisfied.
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7 The section of pipeline to be lined shall have been cleaned, surveyed and repaired to the
requirements of this section of the standard specification prior to liner installation.
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8 For each length of liner two samples shall be taken at locations determined by the Engineer.
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Sampling method shall include the use of a former to replicate the host pipe. The samples
shall be clearly labelled with date taken and location. The samples shall be tested for
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average inside diameter, average outside diameter and minimum wall thickness in
accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
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D2412 and for the properties given in Table 2. The stiffness so measured shall meet, or
exceed the stiffness requirements determined by calculation for that section of sewer line or
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the minimum specified stiffness whichever is greater. Any material may be rejected for failing
to meet any of the requirements of this specification.
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9 The watertightness of the pipe shall be gauged while curing and under a positive head.
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10 The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to the
manhole liner using a material that is compatible with the liner.
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11 Wrinkles in the finished pipe which exceed 5% of the pipe diameter are unacceptable and the
liner shall be removed and a replacement liner installed to the approval of the Engineer.
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11.7 SPIRAL WOUND PROFILE LINER

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11.7.1 Scope
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1 The scope of work consists of rehabilitation of sewers by the installation of helically wound,
profile walled thermoplastic pipe.
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11.7.2 Materials
1 The physical properties of the PVC-U material used in the production of the liner shall
conform to the cell classifications 12454C or 1236C, as defined by ASTM D1784.
Notwithstanding this requirement, the material shall meet or exceed the following physical
properties, as given in Table 11.2:
Table 11.2
Physical Properties of PVC-U Material
Property Value
Flexural Modulus (Short Term) 2400 MPa

Flexural Modulus (Long Term) 800 MPa
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Tensile Strength (Short Term) 45 MPa
Tensile Strength (Long Term) 20 MPa
70 C
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Heat Distortion Temperature
Specific Gravity 1.4
Allowable Long-term Strain 2%
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Hardness (Shore D) 80
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2 The base material for the liner shall consist of a profile walled strip, extruded from PVC-U or
other thermoplastic material, approved by the Engineer in accordance with ASTM F 1697. All
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materials shall be resistant to internal exposure to potable water, sea water, sewage, sewer
gases, and reagents listed in Table 11.3, when tested in accordance with the provisions of
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ASTM D543, to a temperature of 35 C:
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Table 11.3
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Resistance of Liner Material

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Reagent Concentration
Nitric Acid 5%
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Phosphoric Acid 10 %
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Sulphuric Acid 10 %
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Detergent 0.1 %
Soap 0.1 %
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3 Where high liner stiffness is required to resist external loads, the strength of the liner may be
enhanced by the provision of plastic-coated stainless steel reinforcement wound into the liner
at the time of installation. The steel reinforcement shall consist of stainless steel type 316L
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and shall be coated with a low density polyethylene coating or other material approved by the
Engineer, not less than 1 mm thick. The steel shall meet or exceed the following physical
properties given in Table 11.4:
Table 11.4
Physical Properties of Steel
Property Value
Tensile Strength 250 MPa

Modulus of Elasticity 195 GPa
9 x 10 / C
-6
Coefficient of thermal expansion
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4 For each length of liner a sample shall be prepared prior to the winding machine being placed
into the manhole. A length of pipe shall be formed from the same batch of material to be
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used in the installation. The length of sample shall be such that three lengths may be cut and
tested in accordance with ASTM D2412 for pipe stiffness at 5% deflection and for the
properties given in Table 4. The stiffness so measured shall meet, or exceed the stiffness
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requirements determined by calculation for that section of sewer line or the minimum
specified stiffness whichever is greater. Any material may be rejected for failure to meet any
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of the requirements of this specification.
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5 Each liner shall be clearly marked by the manufacturer with the following information:
Manufacturer’s name
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Manufacturer’s production code from which plant location, machine and date of manufacture
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can be identified
The project or contract number
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6 At the time of installation the liner shall be homogenous throughout, uniform in colour, free of
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cracks, holes, foreign materials, blisters and deleterious faults.

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7 This method may only be used for pipes of 250mm diameter or greater.
11.7.3 Installation of Spiral Wound Profile Liner

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1 The installation of spiral wound liner shall follow the recommendations of ASTM F-1698.
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2 Spirally wound profile liners shall be installed using a winding machine placed at the bottom
of the manhole, with the liner being introduced at a diameter of approximately 25 mm less
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than the minimum diameter of the pipeline to be rehabilitated. After the liner has been
installed, the annular gap shall be filled with a cementitious grout or the liner shall be
expanded until it comes into intimate contact with the host pipe.
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3 Jointing of the liner shall be accomplished by the use of an adhesive material suitable for use
with the liner material. The adhesive shall be fully resistant to the corrosive sewer
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environment and shall be applied to the strips at temperatures of 35 to 50 C. Alternatively

the liner shall be joined using a mechanical locking strip. The strip shall have mechanical and
chemical resistance properties that are not less than those of the liner material. The joint
shall be continuous and watertight for the full length of the sewer. The interface between the
liner and manhole shall be sealed with material specified in Clause 11.10.3.
4 Grouting of the annulus shall be carried out using the differential pressure method. The liner
shall be filled with water and maintained at a constant pressure that is greater than the
grouting pressure. Failure to maintain pressure in the pipeline will indicate that a defect
exists. The water pressure shall be monitored via a gauge fitted to the grout plug, whereas
the grouting pressure shall be monitored via a gauge fitted at the end of the grout hose.
When water direct from a potable supply is used, an anti-siphon device shall be used to
prevent contamination. Grouting shall be continued until there is a consistent flow of grout at
the upstream manhole. Should grout pressure build up, before a show of grout is observed,
the injection shall be stopped immediately to prevent damage to the liner. A sample of the
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grout shall be taken during grouting and its curing time monitored.
5 Alternative grouting methods that are specific to a particular lining system will be allowed only
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with the approval of the Engineer.
11.8 PIPE CRACKING OR BURSTING
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11.8.1 Scope
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1 Rehabilitation of sewers by the replacement of existing pipes with polyethylene (PE) or
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polypropylene (PP) pipes by breaking the existing pipes, expanding the hole size and
inserting the replacement pipes in one operation with a minimum of disturbance to the
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surrounding ground and no surface disruption.
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11.8.2 General
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1 The Contractor shall satisfy the Engineer that the pipe bursting procedures will not have
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detrimental effects on adjacent utilities or structures, particularly from vibration arising from
use of pneumatic bursters. The Contractor shall be responsible for such damage and shall
bear the cost of rectification.
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2 The Contractor shall comply with the requirements of service authorities and shall be
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deemed to have identified the location of services which may be affected by the Works.
Unless otherwise required by the service authorities, where services are known to be located
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within one meter of the pipe to be burst, the Contractor shall expose the service in advance
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of pipe bursting. A minimum free space of 500 mm shall be created beneath the service over
a length to be agreed between the Contractor and the service authorities.
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11.8.3 Materials
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1 The materials used for replacement of the existing pipes shall be polyethylene or
polypropylene unless otherwise specified in the contract documents.
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2 The method of jointing the pipes shall be as the manufacturer’s recommendations for the
application. Unless otherwise specified or approved by the Engineer pipe joints shall be
designed to be watertight against external water pressure assuming that groundwater
extends to the ground surface.
11.8.4 Installation Equipment
1 Pipe bursting equipment shall be hydraulically or pneumatically powered incorporating an

expander at the nose of the machine which will fragment the existing pipe and expand the
space uniformly to a diameter sufficient to allow the replacement pipe to be inserted. The
annular space between the expander and the replacement pipe shall not exceed 20 mm
unless otherwise agreed by the Engineer.
2 The method of inserting the replacement pipe shall be such that stresses transmitted to the
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replacement pipe shall not damage the pipes or exceed the tensile capacity of the
replacement pipe.
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3 Pipe bursting equipment shall be capable of
(a) Working from existing manholes so that they can be used as launch and reception
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shafts wherever possible. Provision shall be made for remote starting and stopping.
(b) Dealing with small quantities of unreinforced concrete of maximum 150 mm nominal
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thickness found surrounding pipes, joints, saddles and service connections and for
bursting pipes laid on a concrete cradle without being deflected off line and level.
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(c) Working under a hydrostatic pressure of groundwater.
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(d) Operating at maximum depth of 10.0 m from surface level.
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(e) Operation without jamming of moving parts or other malfunction due to the ingress of
groundwater or sand particles.
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4 Where the Contractor has not previously used the equipment or demonstrated the pipe
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bursting technique to the satisfaction of the Engineer then he shall demonstrate the suitability
of the equipment as follows:
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(a) construct in open ground at a location approved by the Engineer, a 50m long
temporary section of pipe of the same bore and material as the sewer to be
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rehabilitated at similar depth, complete with unbenched chambers at each end;

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(b) backfill the excavation;

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(c) demonstrate the pipe bursting procedure.

(d) on completion of the pipe installation flood the site to artificially bring the water table to
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the ground surface and demonstrate that infiltration requirements of Part 4 of this
Section are met.
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5 Should difficulties be encountered in completing the trial installation the Contractor shall
modify his proposal for approval by the Engineer before recommencing work.
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6 Measures shall be taken to ensure that the replacement pipe does not become separated
from the pipe expander should the system employ an insertion technique which allows the
replacement pipe to slide within the pipe expander.
11.8.5 Installation
1 Shafts for launch and reception shall be existing manholes and excavations made over
existing inspection chambers and service connections where the latter are proposed to be
reconnected to the pipeline. Service connections to be abandoned or redirected to upstream
or downstream chambers or manholes shall not be excavated.
2 Unless specifically approved by the Engineer pipe bursting shall not be carried out by
constructing shafts adjacent to manholes. Where necessary, the channel, benching and
walls of existing manholes shall be altered to receive the pipe bursting equipment. All
manhole alterations shall be made good.
3 The Contractor’s attention is drawn to the potential problems arising from the inflow of
groundwater and loss of ground from the outside of manholes. His proposed method of
working shall take these into consideration and shall be subject to the Engineer’s approval
and shall ensure that no inflow of groundwater or loss of ground occurs. Where manholes
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are located in roads, the Contractor shall obtain permission from the Roads Division prior to
carrying out any wellpoint dewatering operations around the manhole. In the event that
means of stabilising the ground around the manhole and connecting pipelines are not
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approved by the Engineer, the Contractor shall not use pipe bursting methods at that location
unless any other alternative method is approved by the Engineer.
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4 Existing service connections shall be disconnected from the existing pipeline in advance of
pipe bursting and reconnected on completion of the installation of the replacement pipe. In
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the interval, the Contractor shall maintain service by temporarily connecting service
connections to the sewerage system downstream of the section, by overpumping, or by such
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other method the Contractor may propose for the Engineer’s approval.
5
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Sewer lengths to be rehabilitated shall be checked for the presence of collapses occurring
subsequent to cleaning by gauging between shafts. Where a collapse is detected its position
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shall be determined and an additional shaft shall be excavated if the debris cannot be
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removed.
6 Pipe bursting shall not commence unless sufficient lengths of replacement pipes are
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available on Site to complete the length of pipe to be rehabilitated.

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7 Where pipe bursting is delayed for a period exceeding 7 days following cleaning, the pipeline
shall be reinspected.
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8 Winching shall conform to the following requirements:

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(a) Details of the proposed winching method shall be submitted to the Engineer for
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approval at least 7 days before the insertion date

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(b) Winches shall be of the constant load type fitted with a direct reading load gauge. At
the end of each day’s work, the Contractor shall provide the Engineer with a copy of
the winching loads recorded at the start of any pull and during the pull at increments of
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20 m of winching distance and at any restart following temporary stops

(c) Winches shall be fitted with an automatic device to disengage when the load
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exceeds a preset maximum load.

(d) The Contractor shall supply sufficient cable in one continuous length to ensure the
pull is continuous between approved winching points
(e) Winches, cables and cable drums shall be provided with safety cages and supports
(f) The Contractor shall provide a system of guide pulleys and bracings at each manhole
(g) Nose cones fixed to the head of pipe expanders shall be fitted with a swivel attachment
to prevent twist transmission between the winch cable and the nose cone
(h) Where the Contractor proposes to use a lubricant to ease the pull, the type of
lubricant, method of introduction, removal and quantity to be used shall be submitted
for the Engineer’s approval before beginning winching
(i) Trench sidewall support in the insertion trench shall remain completely separate from
the pipe support system and shall be designed so as not to be in contact with the pipe
or the winch cable.
9 Replacement pipe shall be inserted in accordance with the following requirements:
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(a) the maximum force shall be within the stress limit of the pipe
(b) continuous length pipelines shall not be used. The maximum pipe length for insertion
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shall be 1.5 m where pipe bursting is undertaken between excavated shafts and either
700 mm or 800 mm where pipe bursting is undertaken from manhole to manhole
(c) where a device is employed to exert force on the rear of the inserted pipe lengths, the
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force applied to the inserted pipe shall be evenly distributed around the wall of the
pipe
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(d) Where lengths of pipe are joined and a device is employed to exert force to the rear of
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the inserted pipe lengths, precautions shall be taken to ensure that no buckling,
crushing, twisting, or damage to the joint of the pipe takes place. Where, in the
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opinion of the Engineer, excessive deformation of the pipe has taken place, the pipe
shall be replaced at the Contractor’s expense.
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10 Where the lining is to be joined using ‘Snap-Lock’ or similar fittings, the Contractor shall
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comply with the manufacturer’s recommendations for jointing. Means of verifying the critical
dimensions of the joints shall be provided on site by the Contractor. The joint shall be fitted
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with a suitable sealing ring and shall be designed to be watertight against an excess external
water pressure of 20 metres head.
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11.9 INSPECTION AND TESTING OF PIPE LINES AFTER REHABILITATION

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1 The completed sewer shall meet the leakage requirements of pressure tests or air tests as
specified in Part 4 of this Section.
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2 After completion of each length of sewer, the Contractor shall flush the pipeline and
undertake a CCTV and deflection survey and provide video tapes, pictures on digital format
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and site coding sheets to the Engineer.
3 Where necessary the Contractor shall remove any debris and carry out any remedial work
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identified. Upon completion of remedial work and removal of debris the section shall be
resurveyed and the Engineer provided with the latest CCTV video tapes. Further additional
CCTV surveys resulting from the need to again clean or carry out further remedial work shall
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be at no additional cost to the Employer.
4 The rehabilitated sewer shall be returned to service only after the written approval of the
Engineer.
5 During the guarantee period any defects which will affect the integrity or strength of the pipe
shall be repaired at the Contractor’s expense, in a manner mutually agreed by the Engineer
and the Contractor.
11.10 MANHOLE REHABILITATION
11.10.1 Scope
1 The scope of work consists of the materials and types and methods of repair for the
rehabilitation of manholes.
11.10.2 General
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1 Manhole rehabilitation shall comprise but not be limited to any combination of the following:
(a) Rehabilitation of walls or bases by plugging, patching, and removing, providing or
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replacing mortars, coatings, sealants and liners, to improve structural condition,
prevent infiltration, provide corrosion protection or external tanking protection.
(b) Repair of shaft and cover slab and reconstruction to the required level
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(c) Reinstallation or replacement of manhole frame and cover
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(d) Installation of manhole sealing plate.
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11.10.3 Materials
1
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Materials used shall be suitable proprietary materials for manhole rehabilitation and the
specific application in which they are used. The materials shall be supplied in factory-labelled
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containers. All materials shall be mixed and applied in accordance with the manufacturer’s
instructions.
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2 Materials used for plugging holes and stopping infiltration in manholes shall be either:
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(a) Premixed hydraulic cement consisting of Portland cement, graded silica aggregates,
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special plasticising and accelerating agents with a set time of approximately 50 s and
a 10 min compressive strength of approximately 3.5 MPa and free of chlorides,
gypsum, plasters, iron particles, or gas-forming agents
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(b) Siliconate-based liquid accelerator mixed with neat Portland cement with a set time of
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approximately 50 s.
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3 Materials used for patching, filling and repairing non-infiltration holes, cracks, and breaks in
concrete and masonry manholes shall comprise a premixed Portland cement-based
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hydraulic cement consisting of Portland cement, graded silica aggregates, special plasticising
and accelerating agents with a set time of approximately 3 min or 15 min to suit application
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and a one-hour compressive strength of approximately 4.2 MPa. It shall not contain
chlorides, gypsum, plasters, iron particles, or gas-forming agents.
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4 Materials used for waterproofing membrane, corrosion protection, and strengthening of

concrete and block work manholes shall be:
(a) liquid polymer modified water based waterproof coating which shall provide a secure
mechanical and chemical bond with a curing time of approximately 1.5 h and a
cured compressive strength of approximately 40 MPa. The coating shall be applied
with a brush to surfaces without cracks or voids wider than 1.5 mm
(b) 100 % solids, three-component system consisting of a two-component epoxy resin

and a special blend of fillers which shall provide a secure mechanical and chemical
bond with an initial curing time of approximately 4 h and a cured compressive
strength of approximately 76 MPa. The resin with fillers shall be applied with a trowel
to a thickness of 3 mm to 12 mm. Epoxy resin (without fillers) used for waterproofing
and corrosion protection shall be applied with a brush.
5 Remove all defective linings together with 100mm of adjoining good lining in existing
manholes and other structures, including areas of lining covering leakage points.
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6 Break out defective concrete to sound concrete surface.
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7 Apply approved epoxy bonding agent and reinstate concrete using an approved concrete
repair material.
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11.10.4 Rehabilitation of Manhole Walls and Bases
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1 Surfaces of manhole walls and bases shall be thoroughly cleaned to remove all loose
material and surface contaminants. Cleaning shall be accomplished by pressure jetting,
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sandblasting, or applying a 10 % solution of muriatic acid or hydrochloric acid. Where an acid
solution is used the surface shall be thoroughly rinsed and neutralised before the application
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of mortars and coatings.
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2 After surface preparation and before the application of mortars and coatings, infiltration shall
be stopped by sealing as specified in Clause 11.3.4.
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11.10.5 Rehabilitation of Manhole Shafts and Slabs

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1 The Contractor shall take all necessary precautions to prevent debris from damaging the
manholes and the sewer.
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2 Shafts and cover slabs shall be repaired and rehabilitated with suitable sound materials
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3 Rings shall be provided as appropriate to reconstruct the shaft to the required elevation.
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11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or Replacement

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1 The Contractor shall remove covers, frames, and sealing plates. Where the Engineer
determines that cover, frames and sealing plates are to be replaced, the Contractor shall
dispose of them.
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2 The Contractor shall adjust the level and slope of the manhole cover as required. The
manhole shall be raised by building precast concrete rings.
3 Covers and frames determined by the Engineer to be in good condition shall be grit blasted
and coated on all exposed faces with a zinc primer and coal-tar epoxy paint finish as
specified for System C in Part 8 of this Section. Replacement covers, frames and sealing
plates shall be as specified in Part 6 of this Section.
4 The Contractor shall reinstall or replace the manhole cover and frame using either of the
following methods in accordance with the Contract Drawings and clause 4.4 of this Section.
5 Sealing plates shall be installed as specified in Part 6 of this Section.
1 Completed rehabilitation works shall be visually inspected in the presence of the Engineer.
Work that has become defective shall be redone at no additional cost to the Employer.
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11.11 MANHOLE LINING
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11.11.1 Scope
1 The scope of work comprises structural rehabilitation of manholes by the installation of in-situ
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glass fibre reinforced manhole liners.
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11.11.2 Materials
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GRP liner materials shall be as specified in Part 7 of this Section.
11.11.3 Installation of Lining

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1 The cover slab and manhole cover shall be removed and disposed of off Site. The manhole
cover and frame shall be thoroughly cleaned, treated with two coats of bituminous paint and
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delivered to CED store and placed into storage.

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2 Step irons shall be removed and the walls made good and prepared with 3:1 sand/cement
mortar.
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3 Concrete surfaces to be lined shall be cleaned and lightly abraded prior to the application of
the GRP. The GRP lining shall be built up by applying isophthalic or vinyl ester resin. A layer
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of ECR glass mat shall then be rolled into the resin using a suitable steel roller to exclude all
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air and provide complete immersion of the glass fibre in the resin. After a period to allow pre-
gel to a tacky state, a second coat of resin shall be applied followed by a further layer of glass
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fibre mat. This process shall be repeated until the total thickness of lining is approximately
4 mm. Vinyl ester resin and “C” glass veil shall then be used to complete the lining.
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4 Top surfaces of benching shall incorporate silica sand to form a non-slip surface.
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5 The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall
be raked out 15 mm deep on the inside face and pointed with an approved pitch extended
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polyurethane sealant.
6 GRP ladders of an approved pattern as specified may be purpose made to suit the depth of
each manhole. Fixings for ladders shall be approved stainless steel stud anchors. Fixing
holes shall be grouted with epoxy mortar and sealed as above. Rungs or treads shall be
ribbed to provide a non-slip surface.
1 After the manhole lining has been installed, the manhole shall be visually inspected in the
presence of the Engineer and subject to the approval of the Engineer.
2 Before the expiration of the Period of Maintenance, the Contractor shall visually inspect the
lined manholes in the presence of the Employer or Engineer. Work that has become
defective shall be redone at no additional cost to the Employer.
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END OF PART
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Part 12: Vacuum Sewerage System
12 VACUUM SEWERAGE SYSTEM .................................................................. 2
12.1 GENERAL ...................................................................................................... 2

12.1.1 Scope 2
12.1.2 References 2
12.1.3 Definitions 2
12.1.5 Submittals 3
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12.1.7 Warranty 4
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12.1.8 System Operation 4
12.1.9 Commissioning 5
12.1.10 Maintenance 5
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12.2 SYSTEM DESIGN AND PERFORMANCE .................................................... 5
12.2.1 General 5
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12.2.2 Design of the System 5
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12.2.3 Design of Vacuum Station 6
12.2.4 Design of Collection Chambers M 7
12.2.5 Design of Vacuum Pipelines 7
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12.3 PRINCIPAL SYSTEM COMPONENTS ......................................................... 8
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12.3.1 General 8
12.3.2 Vacuum Pipelines 8
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12.3.3 Collection Chamber 9

12.3.4 Interface valves 9
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12.3.5 Controller 10
12.3.6 Sensor 10
12.3.7 Vacuum Vessel 10
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12.3.8 Vacuum Pumps 11

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12.3.9 Forwarding Sewage Pumps 11

12.3.10 Motor Control Centre 11
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12.3.11 Telemetry Outstation 12

12.3.12 Discharge Pipelines 12
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12.4 INSTALLATION OF THE SYSTEM ............................................................. 12

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12.4.1 Pipelines 12
12.4.2 Pipe Joints for Vacuum Pipelines 12
12.4.3 Pumps, Motors and Instrumentation 13
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12.5 TESTING ..................................................................................................... 13

12.5.1 General 13
12.5.2 Testing of Interface Valves, Controllers and Sensors 13
12.5.3 Testing of Pipelines 13
12.5.4 Testing of Pumps, Motors and Instrumentation 14
12.6 TRAINING OF EMPLOYER’S PERSONNEL............................................... 14
12 VACUUM SEWERAGE SYSTEM

12.1 GENERAL
12.1.1 Scope
1 This Part includes the specifications for the design and provision of vacuum sewerage
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systems.
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This Section
Part 1 General
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Part 2 Earthworks
Part 3 Pipes and Fittings Materials
Part 4 Pipe Installation
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Part 5 Valves, Penstocks and Appurtenances
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Part 6 Miscellaneous Metalwork
Part 8 Protective Coatings and Painting
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Section 1, General
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Section 21, Electrical Works
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Section 22, Air Conditioning, Refrigeration and Ventilation.

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12.1.2 References
BS 5500, welded pressure vessels
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European Standard CEN/TC 165, Vacuum sewerage system outside buildings.

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12.1.3 Definitions
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1 The following definitions of vacuum sewerage system apply to this Part:

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(a) Batch Volume: volume discharged from a collection sump during one normal cycle of
the interface valve and is equivalent to the volume of the sump within the operating
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range of the sensor.

(b) Collection Chamber: interface between the vacuum sewerage system and the
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collection sewers consisting of a collection sump and interface valve pit.

(c) Collection Sump: storage capacity provided to store flows of sewage until sufficient
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volume has accumulated to activate the interface valve. Storage may also be provided
to reduce the risk of flooding if there is a system failure.
(d) Controller: device which, when activated by the sensor, opens the interface valve and,
after the passage of sewage and air, closes the valve.
(e) Forwarding Pumps: pumps installed at the vacuum station to pump the sewage from
the vacuum system to the trunk sewer.
(f) Interface Valve: valve which admits the flow of sewage and air into the vacuum sewer
through the service connection.
(g) Isolation Valve: valve installed to isolate a particular section in the vacuum sewer
network.
(h) Lift: up-grade section between two down-grade sections of a vacuum pipeline. The lift
height is the difference in sewer invert levels between two successive down-grade
sections. The static lift is the increase in the hydraulic grade line at a lift and is
generally the increase in invert level minus the internal diameter.
(i) Sensor: device which senses the presence of sewage in the collection sump and
activates the controller to open the interface valve.
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(j) Service Connection: that part of the vacuum pipeline which connects a single collection
chamber to the vacuum sewer.
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(k) Vacuum Generator: equipment installed at the vacuum station to generate a vacuum.
(l) Vacuum Pipeline: pipeline under negative pressure.
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(m) Vacuum Pump: pump that creates the vacuum in the vacuum pipeline.
(n) Vacuum Recovery Time: time taken after the operation of an interface valve for the
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negative pressure at the valve to be restored to its original value.
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(o) Vacuum Sewer: the major part of the vacuum pipeline into which the service
connections discharge. M
(p) Vacuum Station: vacuum generators, vacuum vessel (or sewage sump), forwarding
pumps and system controls.
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(q) Vacuum Vessel: negative pressure vessel connected to the vacuum pump. The
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vacuum sewer discharges into the vacuum vessel and the forwarding pumps pump
sewage from the vessel. The vacuum pumps maintain a negative pressure in the
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vessel. When the vacuum generator is an ejector pump, the vacuum vessel is
replaced by a sewage sump at atmospheric pressure.
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1 The Contractor shall be solely responsible for the design and construction of the system to
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meet the specified requirements.

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2 The design of the system shall conform generally with European Standard CEN/TC 165,
except as otherwise specified in this Part.
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3 The vacuum sewerage system shall be required to operate under very low flows but it shall
provide effective transfer of sewage to the sewers under all conditions and not cause flooding
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or overflow of sewage from the collection vessels.

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4 The maximum noise level at the vacuum station and elsewhere in the system shall not
exceed 65 dbA.
12.1.5 Submittals
1 The Contractor shall submit complete data and details of vacuum sewerage systems for the
Engineer’s approval as follows:
(a) method statement which shall include :

(i) name and experience of specialist
(ii) detailed procedure for the works
(iii) list of all construction plant and tools

(iv) safety procedures
(b) hydraulic, structural, mechanical and electrical calculations used in the preparation of
the shop drawings.
(c) shop drawings for all components and the complete system.
(d) certificates that all components and equipment to be provided are suitable and made
of such materials to withstand the prevailing climatic conditions of Qatar and the
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corrosive environment. Details of proposed corrosion protection systems shall be
provided.
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(e) complete justification for any proposed changes in materials.
(f) Training program
(g) operation and maintenance methods manual which shall include:
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(i) complete information of the system illustrated in detailed drawings
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(ii) detailed procedures for correct operation and maintenance of all system
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components.
(iii) reprogramming manual M
2 The Contractor shall not procure materials or commence installation of the Works until the
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Engineer has approved his submittals.
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1 The vacuum system shall be provided by approved, specialist manufacturers, suppliers and
installers designated in the contract Project Specification.
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2 All supervisors and technicians employed shall be fully competent in the installation methods.
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12.1.7 Warranty
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1 The control equipment shall be provided with a satisfactory performance warranty.

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2 In addition to the warranty requirements of Part 1 of this Section, the vacuum sewerage
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system supplier shall warrant that the system and its components will meet the performance
for a period of 24 months from the date of startup. The vacuum system supplier shall be
solely responsible for the warranty. The warranty shall be in the form of a letter and report
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which shall be submitted to the Engineer, for review. Within the warranty period, any
remedies necessary to bring the vacuum sewerage system into compliance with the
specifications shall be the sole responsibility of the vacuum system supplier.
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3 The Contractor shall furnish the Employer with manufacturer’s warranty and guarantee
certificates for all equipment.
12.1.8 System Operation
1 On satisfactory completion, the Contractor shall operate and run the vacuum system for a
period of 400 days during which time he shall be totally responsible for all maintenance
including spares.
12.1.9 Commissioning
1 The Contractor shall submit instruction manuals in draft to the Engineer four weeks prior to
the commissioning.
2 The Contractor shall demonstrate to the Engineer that all equipment functions to meet the
design criteria and specifications.
12.1.10 Maintenance
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1 The Contractor shall provide any special tools and equipment needed to operate and
maintain the system and provide spare parts for two years operation and an additional 400
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days for the maintenance, all at his expense.
12.2 SYSTEM DESIGN AND PERFORMANCE
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12.2.1 General
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1 The vacuum system shall be supplied by a manufacturer approved by the Engineer.
2
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The general location of the vacuum sewerage system including the locations of collection
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chambers, vacuum pipelines, vacuum station and pressure pipeline discharging to the trunk
sewer which forms part of the gravity sewerage system shall be as shown on the Drawings.
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3 The Contractor shall be responsible for carrying out any additional site investigations, for the
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design, and for provision of a complete system including supply of all materials and
equipment, testing, startup and commissioning.
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12.2.2 Design of the System

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1 The design of the system shall satisfy either of the two conditions:
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(a) outline design of the sewerage system provided by the Engineer

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(b) as an alternative option proposed by the Contractor to avoid deep sewers in the
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Contract in which case the design will be based on the Contract Drawings
2 The Contractor shall not procure materials, equipment or begin construction of the Works
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until the Engineer has approved the design and all other submittals.
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3 The vacuum sewerage system shall intercept sewage flow and convey the flow to collection
chambers. Collection chambers, interface valves and vacuum pipelines shall be located so
that they do not interfere with or obstruct existing services and access thereto.
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4 Sewage from the collection chambers shall be drawn into the system through interface valves
and conveyed by the vacuum pipelines to a collection vessel located in the vacuum station,
equipped with vacuum pumps.
5 Sewage from the vacuum station shall be pumped through the pressure pipeline to the
gravity sewerage system. All necessary pipework shall be included from the vacuum station
to the point of discharge to the gravity sewer.
12.2.3 Design of Vacuum Station
1 The Contractor’s design shall optimise the number and locations of the vacuum stations.
Where more than one station is required, the size of the collection vessels, vacuum pumps
and other equipment shall be standardised as far as practicable.
2 Vacuum stations shall comprise all civil works; mechanical and electrical works including
pipework, vacuum vessel, vacuum pumps, cooling systems, forwarding pumps, odour control
equipment; motor control centre; instrumentation including vacuum data loggers, and valve
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telemetry display and telemetry outstation and connection to the control centre; lighting and
all other work necessary in accordance with Sections 9 and 21 to make the vacuum station
complete in all respects.
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3 Forwarding pumps shall be controlled by level probes installed in the collection vessel; two
sets of probes shall be installed, an upper set to run on normal day operation and a lower set
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to empty the vessel under extreme low flow conditions. The pump control station shall include
automatic timer, indication and alarm in accordance with Sections 9 and 21.
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4 The vacuum station shall be of cavity wall construction. The Contractor shall design the
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station building and submit detailed design drawings for the Engineer’s approval. The station
building shall incorporate the following minimum requirements:
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(a) minimum internal floor area 12 m
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(b) external cement, sand or concrete blocks

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(c) aluminium doors and window frames

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(d) black PVC-U rainwater drainage connected to surface water drainage conduits if
available, otherwise to a gargoyle and soakaway
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(e) sufficient wall area for telemetry outstation

(f) QGEWC supply meters to be mounted in external box (QGEWC supply)
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(g) a connection point to the incoming vacuum sewer, fitted with an isolation valve, for
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independently testing vacuum valves

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(h) a separate room housing a single water closet and hand basin with both hot and cold
running water
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(i) water supply to a 200 l GRP header tank above the roof
(j) external washdown tap with concreted splash area below, draining to the on-site
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vacuum collection chamber

(k) activated carbon type exhaust air filter
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(l) a collection chamber shall be constructed at the site which shall receive the flows
from the water closet, hand basin, external washdown tap, and coolant water from
the liquid ring vacuum pumps.
5 The vacuum station shall include all pipework necessary for satisfactory performance,
operation and maintenance.
12.2.4 Design of Collection Chambers
1 Collection chambers shall be designed such that in each case the lowest invert of the
incoming gravity sewer is above the high operation sewerage level of the interface valve to
avoid surcharging the gravity sewers during normal operation.
2 Collection chamber sumps shall be sized to give a 4 h retention capacity at average flow
below the level of the incoming sewers. The Contractor shall account for the probability of
power failure and its consequences. Provision shall be made in the control panel and cabling
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for connecting mobile standby power generation.
3 Collection chambers shall be fitted with a level sensing devices and local and remote alarms
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as designated, and shall be so located and fitted with access openings to enable clearing of
sewage using pumping or vacuum tankers. In no case will the provision of facilities for
discharge of sewage to the surface water drains be permitted.
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4 Collection chambers shall incorporate an intermediate platform within the chamber to
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facilitate easy access to the vacuum interface valve. The area of the platform must be at
least equal to half the plan area of the chamber. Access to the lower part of the chamber
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below the intermediate platform shall be provided with a minimum 600 mm diameter clear
opening. Where the intermediate platform is provided by means of a concrete slab, the
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access hole into the lower chamber shall be provided with a galvanised open mesh cover as
specified in Clause 6.5.7 of this Section permitting viewing of the lower part of the chamber
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from the top of the chamber.
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5 Vacuum interface valves in collection chambers shall incorporate an auxiliary suction pipe
such that if the valve fails the chamber can be emptied into the vacuum pipeline. The
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auxiliary suction pipe shall be positioned within 100 mm below the cover level and shall be
operable from ground level outside the chamber.
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6 Interface valve assemblies shall incorporate isolating valves such that the interface valves
can be easily removed without necessitating loss of vacuum in the vacuum pipeline.
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7 Where breathers are used on vacuum interface valves they shall not exceed 5 m in length.
Where the breather head is not against a structure to which it can be securely fixed the
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breather head shall be protected by a 50 mm by 50 mm galvanised steel angle cast in

concrete, the head being fixed into the angle with plastic cable ties or similar. Where any
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double valve collection chambers are used each valve shall have a dedicated breather.
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8 The sump shall be vented to allow the intake of air. The sump may be vented by the gravity
system provided that the operation of the vacuum system does not unseal the traps on the
internal sewerage system and that the internal sewerage system is vented to atmosphere.
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12.2.5 Design of Vacuum Pipelines
1 Pipeline profiles shall be as follows:
(a) the size of individual lifts shall be kept as small as possible to maximise vacuum
transport efficiency and many small lifts shall be provided instead of one large lift.
The minimum horizontal distances between profile changes shall be 6 m for vacuum
sewers and 1.5 m for service connections
(b) except at lifts, vacuum sewers shall have a minimum gradient of 1:500 in the
direction of flow. Profile changes shall be made where necessary to ensure that the
pipeline depth does not become excessive
(c) where the ground surface has a gradient of 1:500 or more in the direction of flow,
vacuum sewers may be laid parallel to the surface. Stagnation of sewage shall be
avoided at locations followed by an uphill section
(d) lifts shall generally not be more than 1.5 m, but where conditions are such that a lift
exceeds 1.5 m special care shall be taken in the design of pipelines by taking into
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consideration the flow capacity and total lengths of the vacuum pipeline.
2 Air Flow. The total average air/liquid ratio shall not be less than 1.5:1. The Contractor shall
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identify in his calculations the average air liquid flows for which the system is designed.
3 Minimum Negative Pressure. The system design shall achieve a minimum negative pressure
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of 25 kPa (gauge) under no flow conditions at each interface valve.
4 Vacuum Recovery. The system shall be designed so that the vacuum recovery will be fast
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enough to ensure that temporary surcharging of collection chambers does not occur under
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normal flow conditions.
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Length of Vacuum Sewers. Lengths of vacuum sewers shall be such to enable the system to
restart automatically and recover vacuum following rectification any breakdown.
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6 Service Connections. Service connections shall slope away from the interface valve and
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shall connect into the top sector of the vacuum sewer contained within the angle of +60 
about the vertical axis.
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7 Branch Connections. Branch connections to vacuum sewers shall be by junctions connected

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to the sewer above the horizontal axis, and the angle of the junction shall ensure that the flow
towards the vacuum station is generated and backflow is minimised. No connection shall be
made within 2 m of a lift.
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8 Isolating Measures. Adequate means of isolating lengths of vacuum sewer to permit

maintenance shall be provided by isolating valves or appropriate inspecting pipes. Isolating
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valves shall be suitable for service under vacuum and pressure and shall be capable of
sustaining a differential vacuum of 80 kPa.. Buried valves shall be provided with extension
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spindles and surface boxes.
12.3 PRINCIPAL SYSTEM COMPONENTS

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12.3.1 General
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1 All materials used in the manufacture of collection chamber, interface valve and controller
shall be capable of resisting corrosion from soils, groundwater, sewage and sewage gases.
12.3.2 Vacuum Pipelines
1 Vacuum sewers shall have a minimum diameter of 80 mm and service connections shall
have a minimum diameter of 50 mm.
2 All vacuum pipes and fittings shall be of MDPE as specified in Part 3 of this Section. The
minimum pressure rating for plastic pipes shall be 0.6 MPa but higher ratings shall be
employed if the pipe has an initial ovality or if progressive deformation is likely to occur.
3 Pipelines and components shall be designed to withstand the stresses arising from earth
cover, traffic and cyclic loads, particularly at connections to structures and the range of
negative pressures arising during operation and testing.
12.3.3 Collection Chamber
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1 The chamber shall be watertight and shall be protected against floatation in waterlogged
areas. The internal surface of the sump shall be smooth and the sump shall be designed to
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be self-cleansing.
2 Access to the chamber shall be through a manhole cover and frame as specified in Part 4 of
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this section. The size of chamber shall be similar to inspection chamber on the Contract
Drawing.
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12.3.4 Interface valves
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1 Interface valves shall be all ABS construction and shall be capable of performing sufficient
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cycles to evacuate 3000 m3 without attention. All materials shall be serviceable at 50 C
ambient temperature and 100 % humidity conditions except if the valves are exposed to the
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sun where the temperature could reach 80oC. The valve mechanism shall be explosion
proof.
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2 Interface valves shall:

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(a) be minimum of 80 mm diameter and capable of passing solids with a maximum

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size of 65 mm diameter with a visual flow through area of not less than 60 %
(b) be complete with controller, sensor pipework, fittings and telemetry connections
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(c) be vacuum-operated in opening and spring-assisted in closing

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(d) be controlled by sump liquid level and by vacuum

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(e) fail safe in the closed position

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(f) prevent backflow to the collection sump

(g) evacuate the batch volume on each cycle.
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3 Batteries shall not be used in valve actuating or control elements.

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4 Valve opening initiation level and valve opening times shall both be adjustable.
5 Configurations shall be such that the vacuum ensures positive valve seating.
6 When the valve is open, the flow stream shall not be obstructed by the valve plunger. The
valve may be protected from obstruction by the installation of constriction in the suction lift
pipework.
7 The internal diameter of the suction pipe shall not be greater than the internal diameter of the
interface valve which shall not be greater than the internal diameter of the service
connection.
8 Valves installed in sumps shall be capable of operating when submerged in sewage.
9 Valves shall be designed to allow easy access for maintenance. Fixing arrangements shall
enable the valve and control system to be readily replaced.
12.3.5 Controller
1 Controllers shall
(a) be explosion proof
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(b) open the interface valve only if there is a minimum vacuum of 15 kPa available
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(c) maintain the valve fully open until the sump has been fully emptied
(d) be adjustable so that a range of air to sewage volume ratios can be obtained.
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2 If the introduction of air is allowed after the sewage has been fully emptied, the controller
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shall maintain the valve in the open position for a further period.
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12.3.6 Sensor
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1 The interface valve shall be provided with a sensor to determine the level of sewage in the
collection sump. The sensor shall be designed to be fouling resistant. Where level sensor
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pipes are employed they shall not be less than 45 mm diameter.

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12.3.7 Vacuum Vessel

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1 Flows from vacuum pipelines discharged to vacuum stations shall be collected in a vacuum
vessel. The vessel shall be manufactured of steel and be in accordance with the
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requirements of BS 5500 or other corrosion resistant material such as GRP. The steel shall
be corrosion protected in accordance with Clause 8.4.2 of this Section.
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2 Vessel capacity shall suit vacuum generator and forwarding pump capacities and the vacuum
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rate of inflow and storage volume.

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3 Vessels shall
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(a) be fabricated and tested for a working vacuum of 70 kPa and rest vacuum of 90 kPa
(b) be fitted with the required number of correctly sized sewage inlet and outlet
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pipes which shall be integral with the vessel. No inlet pipes shall be connected
below the system emergency stop level. The inlet and outlet pipes shall be
located such that solids do not accumulate in the vessel
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(c) be provided with a suitable flanged manhole access cover to permit entry for internal
inspection and maintenance
(d) be fitted with a level control system which is suitable for operation in vacuum and
easily removed for adjustment or replacement
(e) be fitted with suitable galvanised mild steel cradles for bolting to the concrete floor
of vacuum station.
4 The pump manufacturer’s advice on the need to install equalising lines connecting the
discharge side of the pumps to the vacuum vessel shall be sought. If required by the pump
manufacturer, a suitably sized and valved equalising line from each pump to the vessel shall
be provided
5 The steel vessel shall be internally and externally protected from corrosion with a suitable
protection system in accordance with Part 8 of this Section. Details of the proposed
protection method shall be submitted as required by Clause 12.1.5 of this Section. The
protection system shall take account of accessibility for inspection and maintenance.
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12.3.8 Vacuum Pumps
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1 Two vacuum generators such as liquid ring or rotary vane pumps or ejector pumps shall be
provided each having sufficient capacity to serve the system.
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2 Vacuum pumps shall be capable of continuous operation and shall be designed for a
minimum of 12 starts per hour. Pumps of equal capacity shall be installed such that one
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pump can act as standby.
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3 Vacuum pumps shall be operated by pressure switches attached to the vacuum vessel. The
pumps shall operate on the liquid ring principle and shall exhaust air from the vacuum vessel.
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One duty and one standby vacuum pump shall operate in conjunction with a common tank
containing the operating liquid, normally water, and associated pipework connecting the
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pumps to the tank so that the water level is maintained at all times. The service liquid shall be
maintained at 30 C by a refrigerated cooling unit, circulating the liquid through the tank.
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Ambient air temperatures up to 50 C shall not limit the functioning of this equipment or
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cause the vacuum pumps to trip on high circulating water temperature.
4 Each pump shall be provided with a rotary seal comprising a rubber seal, spring loaded and
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rotating against a carbon face. Suitable non-return valves shall be provided to prevent the
exhausted air from returning into the vacuum system. The pressure switches shall control
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the operation of the vacuum pumps to maintain the vacuum within the system.
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12.3.9 Forwarding Sewage Pumps

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1 Forwarding pumps or pressure vessels used to forward the sewage shall have sufficient
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capacity to serve the system. Forwarding pumps shall be as specified in Section 9 except as
modified below.
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2 Forwarding pumps shall be unchokeable sewage pumps suitable for operating under
negative pressure without cavitations. They shall be suitable for a maximum of 12 starts per
hour. The motor speed shall be 1500 rpm.
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3 A 25 mm connection of swept flanged tee shall be provided on each pump delivery, with
hand hole incorporated in the impeller casing or duckfoot bend under the pump and
reversible wear plate fitted under the impeller. Pumps shall be fitted with lip seals to prevent
loss of vacuum from the shaft when pumping from the sewage vessel.
12.3.10 Motor Control Centre
1 The motor control centre for the operation of all pumps shall be as specified in Sections 9
and 21.
2 The operation of pumps shall be controlled by a programmable logic controller and shall
prevent simultaneous starting of the vacuum and sewage pumps to prevent surges.
3 The controls shall permit the manual or programmed selection of duty and standby pumps
and shall provide for automatic start of the standby pumps in the event of duty pump failure.
4 The vacuum pumps shall be controlled by monitoring the vacuum in the vacuum vessel with
adjustable pressure switches set to the desired operating range. Additional pressure devices
shall be provided to indicate and record both high and low vacuum.
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5 The level control system shall respond to the following sewage levels in the vacuum vessel or
the sewage sump:
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Emergency stop level (High Level) - stops vacuum generation
- forwarding pumps operate
Start level - starts forwarding pumps
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Normal stop level (Low Level) - stops forwarding pumps.
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6 All power, control and instrumentation cabling shall be provided as required for the complete
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system.
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The following alarms with appropriate remote signalling shall be provided:
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(a) low vacuum alarm indicating that system vacuum is below the minimum preset level
(b) high sewage alarm indicating that sewage level in the vacuum vessel or sewage sump
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is at the high level mark.

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12.3.11 Telemetry Outstation

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1 Telemetry shall be designed and installed in accordance with Section 10.
12.3.12 Discharge Pipelines

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1 All pipes, fittings and valves on the discharge side of the forwarding pumps shall be as
specified in Parts 3 and 5 of this Section.
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12.4 INSTALLATION OF THE SYSTEM

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12.4.1 Pipelines
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1 Vacuum and pressure pipelines shall be installed in accordance with Part 4 of this section
and valves shall be installed as specified in Part 5 of this Section, except where modified
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herein.
2 Vacuum pipelines shall be jointed as specified herein.
12.4.2 Pipe Joints for Vacuum Pipelines
1 Pipeline components shall be connected in such a way that the pipeline is sealed and
accommodates static and dynamic stresses.
2 Where mechanical joints are employed they shall comply with the requirements of Part 3 of
this Section and be suitable for vacuum service.
3 Pipelines shall be securely anchored or bedded to resist thrust arising from internal vacuum.
Precautions shall be taken against flotation where necessary.
4 Welded joints shall only be made by suitably trained personnel using approved welding
equipment.
12.4.3 Pumps, Motors and Instrumentation
1 Pumps shall be installed as specified in Section 9.
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2 Motors shall be installed as specified in Sections 9 and 21.
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3 Instrumentation shall be installed as specified in Section 10.
12.5 TESTING
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12.5.1 General
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1 The Contractor shall prepare and submit his proposed testing program for the approval of the
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Engineer.
2
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The Engineer shall be notified 24 hours in advance of testing.
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3 Pipelines and equipment shall be adequately restrained before testing.
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4 On satisfactory completion of testing, the Contractor shall submit a report describing the tests
undertaken and the test results.
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12.5.2 Testing of Interface Valves, Controllers and Sensors

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1 Interface valves, controllers and sensors shall be tested to demonstrate that they function
correctly to meet specified duties.
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2 Where new valves or controllers are introduced or significant changes are made to proven
valves, laboratory tests shall be undertaken under simulated working conditions and test
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certificates provided. The tests, using water and air, shall demonstrate that the complete
valve mechanism can comply with the preceding performance requirements.
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12.5.3 Testing of Pipelines

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1 Pipelines shall be pressure and vacuum tested.

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2 Pressure tests shall be carried out in accordance with Clause 4.5.3 of this Section.
3 Before carrying out a vacuum test, the Contractor shall ensure that the test equipment is
calibrated, is in working order and correctly fitted to the pipe.
4 The permitted loss of vacuum in pipeline tests shall be corrected to allow for changes in
temperature and atmospheric pressure. Pipe temperatures atmospheric pressure shall be
recorded at the start of the test and at hourly intervals.
5 Regular vacuum testing and final vacuum testing shall be carried out as specified herein. In
the event of failure under either test, the leaks shall be located and repaired, and the tests
redone.
6 Regular vacuum testing of all service connections and vacuum sewers shall be carried out on
the pipelines before backfilling and in sections as approved by the Engineer. The test
duration shall be 1 h. Open ends of pipeline shall be capped and a vacuum of 80 kPa applied
and allowed to stabilise for 15 min after which time the fall in vacuum shall not exceed 1.0 %
over the 1 h test.
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7 Final testing of service connections, vacuum sewers and vacuum vessels shall be tested
before the installation of the interface valves. The test duration shall be 4 h. A vacuum of
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80 kPa shall be applied using the vacuum pumps in the vacuum station. Instrumentation shall
be provided to record system vacuum during testing. After the vacuum has stabilised, the fall
in vacuum shall not exceed 1.0 %/h for each hour of the test.
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12.5.4 Testing of Pumps, Motors and Instrumentation
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1 Testing of pumps shall be in accordance with Section 9.
2
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Testing of motors shall be in accordance with Sections 9 and 21.
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3 Testing of instrumentation shall be in accordance with Section 10.
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12.6 TRAINING OF EMPLOYER’S PERSONNEL

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1 The Contractor shall prepare and submit a training program and manual for the approval of
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the Engineer. The training shall cover system installation, operation and maintenance, and
record keeping and interpretation.
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2 On-site training shall be provided by the system manufacturer specialist staff for a minimum
period of 90 days.
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3 The Contractor shall provide facilities required for implementation of the training program.
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END OF PART
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Part 09: Trenchless Pipeline Construction
9 TRENCHLESS PIPELINE CONSTRUCTION ................................................ 3
9.1 GENERAL ...................................................................................................... 3

9.1.1 Scope 3
9.1.2 Related Sections and Parts 3
9.1.3 References 3
9.1.4 Definitions 3
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9.1.6 Submittals 3
9.1.7 Specialist Subcontractor 5
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9.1.9 Site Conditions 5
9.2 TRENCHLESS PIPELINE CONSTRUCTION GENERALLY ......................... 5
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9.2.1 Scope 5
9.2.2 Surveys and Setting Out 5
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9.2.3 Monitoring Lines and Levels 6
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9.2.4 Temporary Site Facilities 7
9.2.5 Safety Requirements M 7
9.3 MATERIALS .................................................................................................. 7
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9.3.1 Pipes 7
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9.3.2 Joint Packing 10

9.3.3 Lubricant 10
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9.3.4 Joint Sealant 10

9.3.5 Grout 10
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9.4 THRUST AND RECEPTION SHAFTS ......................................................... 11
9.5 PIPEJACKING ............................................................................................. 12

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9.5.1 General 12
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9.5.2 Tunnelling Shields for Pipejacking 12

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9.6 MICROTUNNELLING .................................................................................. 12

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9.6.1 General 12
9.6.2 Contractor Responsibilities 13
9.6.3 Safety and Environment 13
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9.6.4 Performance Requirements 14

9.6.5 Micro-tunnel Design Elements 15
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9.6.6 Design Checking 17

9.6.7 Finite Element (FE) and Finite Difference (FD) Models 17
9.6.8 Verification of Results 18
9.6.9 Design Parameters for the Calculations 18
9.6.10 Design Loadings 18
9.6.11 Design Submissions 19
9.6.12 Certification Procedure 20
9.6.13 Contractor’s Documents 20
9.6.14 Construction Responsibilities 21
9.6.15 Quality Assurance/Control 21
9.6.16 Materials 22
9.6.17 Temporary Works 22
9.6.18 Construction Preparation 22
9.6.19 Pipeline Installation 23
9.6.20 Construction Execution 24
9.6.21 Working in Compressed Air 24
9.6.22 Ground Pre-treatment 25
9.6.23 Drainage During Construction 25
9.6.24 Disposal of Tunnel Seepage and Waste Water 26
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9.6.25 Testing 26
9.6.26 Grouting 26
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9.6.27 Surface and Building Settlement Monitoring 27
9.6.28 Contractor’s Obligations 28
9.6.29 Microtunnelling Machine 28
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9.7 THRUST SYSTEM ...................................................................................... 28
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9.8 LUBRICATION HOLES................................................................................ 29
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9.9 RECORDS ................................................................................................... 29
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9.10 TESTING ..................................................................................................... 29
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9.10.1 General 29
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9.10.2 Watertightness 30
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9 TRENCHLESS PIPELINE CONSTRUCTION

9.1 GENERAL
9.1.1 Scope
1 This part includes the specification for the construction of pipelines by microtunnelling,
pipejacking or other trenchless methods approved by the Engineer.
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9.1.2 Related Sections and Parts
This Section
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Part 1, General
Part 2, Earthworks
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Section 1, General
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Section 5, Concrete
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Section 23, Ground Investigation.
9.1.3 References
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BS 2494,.....................Materials for elastomeric seals for joints in pipework and pipelines

BS 5228,.....................Code of practice for noise control on construction and demolition sites
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BS 6164,.....................Code of practice for safety in tunnelling in the construction industry.

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9.1.4 Definitions
1 Pipejacking: technique for constructing pipeline by thrusting pipes or other permanent lining
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of preformed units progressively into the ground by means of jacks or similar equipment
while excavation proceeds at the leading end.
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2 Microtunnelling: small diameter tunnelling technique employing mechanical excavation

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methods usually within a non-man entry guided tunnel boring machine with primary lining
inserted behind by jacking.
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3 Shaft: excavated thrust and reception pits used for tunnelling operations.
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1 The Contractor shall be responsible for the design of the pipes including joints to meet the
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requirements of the method of construction.
9.1.6 Submittals
1 The Contractor shall submit complete data and details for the trenchless pipeline construction
for the Engineer's approvals follows:
(a) Structural design calculations for the trenchless pipeline and temporary works:
(i) the description and specification of pipes and design calculations.
(ii) details of the permitted angular deflection and draw for the proposed pipes.
(iii) the Contractor shall submit full details of the pipes together with details of
previous works undertaken using similar pipes.
(iv) details of proposed manufacturer of pipes with relevant literature and details of
manufacturer's Quality Control system.
(v) anticipated jacking loads.
(vi) structural design of thrust walls.
(b) Shop drawings.
(c) Materials Specifications.
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(d) Method statements which shall include:
(i) details of the specialist sub-contractor's qualifications and experience in micro-
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tunnelling together with project references including previous employers' names
and current contact details and a curriculum vitae of the proposed tunnelling
machine operator including details of relevant experience in Qatar and the
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Middle East.
(ii) detailed procedure for the Works.
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(iii) a description of tunnelling equipment with relevant literature and a statement
from the tunnelling machine manufacturer detailing a delivery schedule for spare
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parts and consumables for the proposed tunnelling machines.
(iv)
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preconstruction activities (geotechnical investigations including test pits).
(v) safety procedures.
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(vi) handling and fixing of the inner pipe in the case of pipe jacking with larger
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diameter pipes.
(vii) programme of work, including proposed production rates.
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(viii) bentonite injection system details.

(ix) detailed method statements for all other aspects of micro-tunnelling work.
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(x) where appropriate for the size of machine proposed, details of man access into
the tunnel and tunnel boring machine.
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(e) Designs of thrust and reception shafts and detailed drawings.

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(f) Dewatering arrangements and disposal of groundwater.

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(g) Methods for dealing with different ground conditions.

(h) Equipment layout at the thrust and reception shafts.
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(i) Details of sleeving system.

(j) Ventilation.
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(k) Lighting and communications.

(l) Disposal of surplus excavated material:
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(i) details of the spoil separation process to produce clean slurry for recirculation to
the tunnel boring machine.
(ii) details of the containment of the excavated material to prevent water and slurry
draining from the Contractor's designated working area or wagons. Lagoons for
storage and settlement of slurry from the micro-tunnelling process will not be
permitted.
(iii) details of the purpose made tanks for settlement of slurry shall be provided.
(iv) details of the solid waste disposal procedure to an approved tip in a manner
which does not cause spillage of slurry, mud or any other solid or liquid waste on
the carriageway.
(v) disposal of surplus water, once all solids have been removed, to an approved
surface/ground water outfall, if locally available, or removed by tanker to an
approved point of disposal.
(m) Pilot bore.
(n) Plan at 1:50 scale showing working plant positions, spoil removal faculties, materials
storage facilities, launch and reception shafts, fencing, offices, discharge lines, ground
water removal facilities, etc.
2 The Contractor shall not procure materials or begin construction of the Works until the
Engineer has approved all submittals. The Engineer’s approval shall not relieve the
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Contractor of his obligations under the Contract.
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9.1.7 Specialist Subcontractor
1 The Contractor shall employ an approved specialist subcontractor experienced in trenchless

methods for the pipeline construction.
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1 The Contractor shall employ an approved prequalified specialist subcontractor as designated
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in the contract specific documentation. All personnel in the employment of the subcontractor
shall be experienced and competent in their respective tasks and shall work only under the
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control of a qualified supervisor.
9.1.9 Site Conditions

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1 The Contractor shall carry out additional geotechnical site investigations which he considers
necessary. The results of such investigations and laboratory testing together with the factual
and interpretive reports shall be submitted to the Engineer for approval. The Engineer’s
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approval shall not relieve the Contractor of his obligations under the Contract.
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9.2 TRENCHLESS PIPELINE CONSTRUCTION GENERALLY
9.2.1 Scope
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1 Where a pipeline is designated in the Contract documents to be constructed by a trenchless

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method, the Contractor shall not be permitted to adopt open trench methods and shall
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confine his surface operations to working shafts and the area immediately adjacent to such
shafts. In locations where construction of pipelines is not indicated to be by trenchless
method, the Contractor may elect to construct additional lengths of pipelines by a trenchless
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method in accordance with this specification, subject to the Engineer’s approval.
9.2.2 Surveys and Setting Out

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1 Before commencing the excavation of any shafts for pipejacking or microtunnelling, the
Contractor shall
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(a) establish at least four adequately protected bench marks comprising steel pins
embedded in a block of concrete adjacent to the shaft to facilitate the setting out of
the underground works
(b) record the initial levels for pipelines beneath or across roads and submit a copy of
these to the Engineer
(c) record and report with supporting photographs of the condition of structures, roads,
footpaths and other paved areas that are located over and beside all jacking or
microtunnelling routes.
2 During construction of a drive between any two working shafts, the Contractor shall observe
levels on predetermined cross-section points at regular intervals to determine if there is any
subsidence.
Temporary benchmarks shall be set up along the centre of the pipe at 15 metre intervals
between the shafts and at 5 and 10 metres offsets. Levels shall be taken along the centre of
the pipeline and at offsets of 5 metres and 10 metres each side of the pipeline at 15 metre
intervals between shafts. Levels shall be taken and recorded on all of the above points at
daily intervals during micro-tunnelling works, again one week before issue of a Completion
Certificate, and finally at the end of the 400 day period of maintenance.
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3 Immediately following completion of the drive between any two working shafts, the Contractor
shall
(a) repeat the level survey of the ground surface along the centreline of the drive as
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described above
(b) record and report to the Engineer with supporting photographs any changes to the
condition of roads, footpaths and other paved areas.
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4 Before the completion of the whole of the Works and again before the expiry of Period of
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Maintenance, the Contractor shall repeat the surveys and inspections as described above for
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all of the trenchless pipeline construction.
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The Contractor shall determine the location of all working shafts having due regard to
existing services, minimising disruption to traffic and pedestrian movements and achieving
the required system layouts, as approved by the Engineer. The Contractor shall prepare
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suitably scaled working drawings for the setting out of the Works, including the location of
existing services and all other relevant details and submit these for the Engineer’s approval.
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6 As-built surveys of each micro-tunnel drive shall be undertaken. For all micro-tunnel drives
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of internal diameter 800 mm or more, including any permitted sleeves of this size, the
Contractor shall employ an approved independent survey company to undertake an as-built
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survey of the drive. Coordinates and levels shall be provided for every pipe joint. For steel
sleeves, coordinates and levels shall be provided at 5 metre intervals. Each completed drive
shall be surveyed immediately after completion of the drive. No further micro-tunnel drives
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may be commenced until the survey results have been submitted to and approved by the
Engineer. No pipes may be installed within sleeves until the survey results have been
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submitted to and approved by the Engineer.

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9.2.3 Monitoring Lines and Levels

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1 A laser guidance system shall be used for the control of the pipe alignment. The shield/tunnel
machine shall be fitted with a calibrated laser target, robustly constructed and rigidly secured
to the shield/tunnel machine.
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2 The setting of the laser and target and the alignment of the tunnel relative to the laser beam
shall be checked frequently at intervals as directed by the Engineer. In addition, the
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Contractor shall verify the accuracy of the laser guidance system by conventional theodolite
and level control methods to the approval of the Engineer.
3 The invert level of the finished pipeline at the drive shaft shall be within ±10mm of the
required level shown on, or interpolated from, the Contract drawings.
The invert level and line of the pipeline shall at no point deviate from the design by more than
the following:
Pipe Bore Vertical Horizontal
D mm mm mm
D < 600 ± 20 ± 25
600 ≤ D ≤ 1000 ± 25 ± 40
1000 < D ≤ 1400 ± 30 ± 100
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D > 1400 ± 50 ± 200
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4 The pipe manufacturer’s stated permitted draw or angular deflection shall not be exceeded at
any individual joint.
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5 If the line and levels of any section of pipeline deviates from the design alignment within the
tolerances the shield/tunnel machine shall be steered in a manner that ensures a gradual
return to the correct alignment.
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6 If the deviation in the lines and levels exceeds the tolerance specified above, the Contractor
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shall stop work and immediately inform the Engineer. The Contractor shall submit proposals
to rectify the deviation. Work shall be resumed only on the written instruction of the Engineer.
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7 Where micro-tunnelled sewers are required to connect into existing pipelines or pipelines
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previously completed under this project, due allowance for the tolerance shall be made prior
to commencing the drive to ensure that the finished pipeline profile does not require the pipe
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contents to flow uphill.

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9.2.4 Temporary Site Facilities
1 In addition to the provisions of Section 1, the Contractor shall provide the following at each
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thrust shaft as a minimum:
(a) air-conditioned mobile office

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(b) telecommunication between the mobile office and the work crews
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(c) adequate ventilation

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(d) approved gas detectors and oxygen meters

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(e) first aid kit.
9.2.5 Safety Requirements

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1 The Contractor shall adopt safe working practices for tunnelling in accordance with BS 6164.
Only authorised personnel shall be allowed access to the Site.
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2 The Contractor shall ensure that a suitably qualified safety officer is present during tunnelling
operations.
9.3 MATERIALS
9.3.1 Pipes
1 Pipe material and the lining and coating shall be as designated in the Project Specification. If
the use of other pipe material or lining and coating is proposed, technical details and
justification shall be submitted for the Engineer’s approval.
2 Pipes shall be designed to withstand the maximum axial thrust with a factor of safety of four
based on the full effective area of the pipe and the ultimate compressive strength of the pipe
material. For reinforced concrete pipes the full effective area at the joint shall be used. The
pipe design shall take into account both permanent service loads and temporary loads
encountered during installation.
3 Where GRP or similar material pipes with concrete surround are proposed the concrete shall
be regarded as sacrificial. The concrete surround shall be designed to withstand the
maximum jacking force. The design shall also ensure that the GRP or similar material pipe
is not subjected to forces during installation. Vitrified clay pipes shall be in accordance with
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Clause 3.2 of this Section.
4 The Contractor’s submittals shall describe the measures to be taken to avoid the
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development and transfer of grout shrinkage and expansion stresses to the pipe and to avoid
any adverse chemical reaction between the pipe and the concrete, grout or other materials
comprising the pipeline. The pipe manufacturer shall guarantee that the crushing and beam
strength of the pipe are sufficient for their intended use.
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5 Joints in pipes shall be designed to avoid projections which could obstruct the travel of the
pipe. Joints shall be watertight under axial loading and at the permissible deflection of the
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pipes. Quality control tests at the factory shall include subjecting the pipe joints, at maximum
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permissible deflection, to a hydrostatic pressure of 0.2 MPa.
6
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Standard pipes shall generally be of 2.0 m in length. Where required, pipes shall incorporate
lubricant injection holes spaced equally around the circumference. Concrete pipes with a
liner shall only be permitted to have lubricant injection holes in the concrete. Lubrication
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holes shall be clear of joints and shall be plugged on completion of the work. Pipes may
incorporate lifting holes and fixing holes for securing temporary apparatus; all such holes
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shall be threaded to enable plugs to be screwed into the sockets to withstand external water
pressures.
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7 Joints which shall be used in conjunction with a resilient packing and shall be capable of
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accepting repeated angular deflections as recommended by the pipe manufacturer without
(a) damage to pipe or loss of structural integrity

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(b) the ingress or egress of water or lubricant under the maximum test pressures
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(c) the ingress of either or both soil or groundwater onto the bearing surfaces.
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8 Unless otherwise directed by the Engineer the joint design for concrete pipes shall be such
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that areas available for transmitting the maximum permitted thrust force will be sufficient to
ensure that with an angular deflection of 1  and with resilient packing material in place, the
maximum pressure applied to the joint bearing surface will not exceed 23.5 MPa for drives up
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to 100 m in length and 21.0 MPa for drives in excess of 100 m in length.
9 Unless Authenticated independent test results acceptable to the Engineer are available, two
consecutive axial load tests incorporating a 1  angular deflection with the application of
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double the maximum permissible thrust force (or, if greater, of the greatest thrust force that
the proposed thrust equipment can apply) shall have been successfully conducted without
visible crushing, cracking or spalling of the pipe being evident, before pipes will be accepted
for use. The tests shall be extended to record the loading at which visible signs of failure
become evident, and shall be carried out in an approved manner to simulate actual working
conditions. Pipes which have been submitted to the proof load test will not be permitted in
the Works.
10 Where the Contractor elects to construct certain sections within larger diameter pipes and
grout the annular space, the external pipe may be of steel. The difference between the
external face of the inner pipe and the internal face of the outer pipe shall not be less than
150 mm. The steel pipe and the grout shall be regarded as sacrificial and the inner pipe shall
be designed as a stand alone pipe, capable of withstanding installation forces and soil, traffic
and groundwater loads.
11 Where the Contractor elects to construct certain sections not within larger diameter pipes,
pipe installation by trenchless methods shall continue until at least one additional length of
pipe beyond the limit of trenchless construction is exposed. The condition of the exposed
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pipe and its exterior coating will be inspected by the Engineer. Where in the opinion of the
Engineer the pipe or coating has been excessively damaged during installation, the
Contractor shall submit a proposal for review by the Engineer, for demonstrating the
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adequacy of the pipeline installed by trenchless methods and for rectifying defects. The
proposal shall also include jacking out of defective pipes.
12 Concrete jacking pipes shall comply with the provisions of BS EN 1916 and BS 5911-1.
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13 Collars shall be manufactured from weldable stainless steel plate Grade 316 Ti (EN 1.4571).
They shall be provided with suitable stainless steel lugs or anchors to enable them to be cast
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into the body of the pipe, if applicable.
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14 Joints in concrete jacking pipes shall be in-wall flexible joints of the fixed collar type. They
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shall be designed to include one or more joint seals. All joint surfaces which will transmit
load during installation shall be plane and free from irregularities that could cause high local
concentrations of stress.
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15 The nominal internal bore of the micro-tunnelling pipes shall be as indicated on the Drawings
or as specified by the Engineer. The Contractor shall select an appropriate external diameter
for the pipe which shall be submitted to the Engineer for approval.
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16 The design of the jacking pipes and determination of acceptable pipe fabrication tolerances
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shall be the responsibility of the Contractor. Maximum compressive stresses applied to the
pipe shall not exceed 33% of the design compressive strength of the pipe and shall not
exceed the pipe manufacturer’s recommended allowable stresses.
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17 Pipes for installation by micro-tunnelling shall be fit for purpose and shall be one of the
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following:
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(a) Concrete designed specifically for jacking to BS EN 1916:2002 and BS 5911-

1:2002+A2:2010 with a GRP pipe lining in accordance with Section 8 Part 3 Clause
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3.4. . The GRP lining pipe shall incorporate watertight joints between adjacent pipes
and shall accept no longitudinal load during jacking. The joint between adjacent pipes
shall be designed to ensure concentricity of adjacent pipes and shall prevent
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application of any lateral forces to the GRP pipe. The coarse aggregate used in the
manufacture of the pipes shall be crushed Gabbro rock. The external surface of the
pipe shall be coated with at least 300 DFT abrasion resistant epoxy. Pipes shall be
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factory manufactured by an approved experienced manufacturer. Pipes shall not be

manufactured on-site.
(b) Concrete designed specifically for jacking to BS EN 1916:2002 and BS 5911-
1:2002+A2:2010 with a polymer lining as described in Section 5 Part 14 Clause 14.6.
The coarse aggregate used in the manufacture of the pipes shall be crushed Gabbro
rock. The external surface of the pipe shall be coated with at least 300 DFT abrasion
resistant epoxy. Pipes shall be factory manufactured by an approved experienced
manufacturer. Pipes shall not be manufactured on-site.
(c) Direct jack GRP pipes to BS ISO 25780:2011 shall be in accordance with Clause 3.4
of this Section.
(d) The joint between adjacent jacking pipes shall be designed to ensure concentric
alignment of adjacent pipes and uniform transfer of jacking forces from one pipe to the
next. The pipe joint shall consist of a substantial external stainless steel guide ring to
achieve this requirement. The joint shall also incorporate one or more EPDM or other
approved elastomeric sealing gaskets.
9.3.2 Joint Packing
1 Packers shall be incorporated into each joint in concrete jacking pipes in order to distribute
the jacking pressure and avoid point loads and to prevent damage to the ends of the pipes
during the jacking process. The packers shall not extend over the full joint width, a gap to the
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inside surface should be left to prevent localised spalling, in accordance with the
manufacturers recommendations.
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2 The material used for packing shall withstand all imposed loadings applied during the
installation of pipes for each completed length without showing signs of deterioration or
distress. The initial thickness of the packing shall be such that the final joint gaps achieved
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upon completion of the pipeline are a normal width of 8 mm.
3 The material proposed for the joint packing and its mechanical properties shall form part of
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the pipe design submission from the Contractor.
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9.3.3 Lubricant M
1 Lubricant shall always be used. Lubricant shall be polymer or bentonite-based slurry
approved by the Engineer. It shall be stored and mixed in a manner recommended by the
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supplier and tested before use. Sufficient quantity of the lubricant material shall be kept
available at Site.
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9.3.4 Joint Sealant

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1 The joint sealant for the jacking pipe shall be of the elastomeric ring type complying with
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BS 2494. Joint sealants shall be stored in a manner recommended by the supplier.
9.3.5 Grout
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1 Grout used for slurry replacement shall

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(a) consist of either ordinary or sulphate-resisting cement and water as determined by

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geotechnical data and directed by the Engineer

(b) have nominal strength at least equivalent to the requirement for Grade 20 concrete.
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(c) have admixtures only if tests have shown to the satisfaction of the Engineer that their
use improves the properties of the grout, such as by increasing workability or slightly
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expanding the grout.
Full details of the proposed grout mix including admixtures shall be submitted to the Engineer
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for approval.
2 Grout used for annular space filling shall
(a) be a low-strength foam concrete placed at low pressures.

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(b) have a mix density in the range 900-1200 kg/m
(c) have free water/cement ratio not greater than 0.6.
The internal pipe shall be filled with water to avoid floatation forces, hydration temperatures
and to resist forces during grouting. A 5 m high free vented standpipe shall be used. A free
venting standpipe of not less than 100 mm diameter shall be installed on the grout injection
feed to restrict grouting pressures to a maximum of 0.1 MPa. GRP carrier pipe and joints
shall be protected from the possible adverse physical or chemical effect of grout, and
compressible material shall be wrapped around the pipe.
9.4 THRUST AND RECEPTION SHAFTS
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1 The dimensions of thrust and reception shafts shall be the minimum necessary to construct
the Works.
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2 Excavations shall comply with the requirements in Part 2 of this Section. Dewatering, if
necessary, shall be conducted at a rate which will minimise the inducement of settlements at
the ground surface. The shafts shall be kept dry at all times.
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3 The thrust wall of the thrust shaft shall be normal to the proposed line of thrust. The thrust
wall shall be sufficient to accept repeatedly the maximum permitted thrust force without
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movement. The Contractor shall not thrust directly from permanent parts of any shaft, or
walls of other structures. The thrust wall shall not be joined to the jacking rig base concrete.
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4 Shaft base slabs shall be capable of withstanding external uplift pressure from groundwater,
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if any, in addition to other imposed loads.
5 Any tail tunnel which has been used as a reaction surface shall pass the designated
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watertightness test at a time not less than 14 days after the load has been removed.
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6 The design of the thrust wall and any other associated temporary works shall be such as to
prevent damage to any part of the permanent works.
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7 Any void between the soil face used to provide a reaction to the thrust force and the thrust
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wall shall be grouted up.
8 Where the excavation is in water-bearing ground, the Contractor shall provide means of
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checking whether any solids are being removed with the water from excavation. Regular
checks shall be made to compare the volume of solids removed with the calculated volume
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as a safeguard against excessive loosening or loss of material beyond the shaft dimensions.
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9 The Contractor shall select the location of the drive and reception shafts. These locations
shall be submitted to the Engineer for approval. These shafts may be incorporated as part of
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the permanent works. All modifications to the shafts converting them into access manholes
shall be completed at the Contractor's own expense. Details of the modifications shall be
submitted to the Engineer for approval and shall conform to those shown on the Contract
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drawings.
10 Prior to commencing work at a shaft, the Contractor shall provide details of the shaft support
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system, working plant position, spoil facilities, material storage facilities, dewatering
arrangements, etc. The details shall include a sketch of all the working facilities at the head
of the shaft.
11 Access down into the shaft for personnel and equipment shall be approved by the Engineer.
Hand railing set at a height of 1 100 mm above ground level together with toe boards and
protective netting to prevent equipment falling into the shaft shall be provided at each shaft.
Fencing shall be erected around each shaft site establishment to prevent the entry of
unauthorised persons.
12 The dimensions of shafts shall be the minimum necessary to safely construct the Works.
13 Backfilling of shafts shall be undertaken in accordance with Section 8 Part 2 Sub-Clause

2.3.3.
9.5 PIPEJACKING
9.5.1 General
1 The maximum lipping between edges of adjacent jacked pipes shall not exceed the
maximum tolerance given in Clause 9.2.3 of this Part.
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2 The horizontal drive rate shall be maintained equal to the excavation rate throughout the
operation.
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3 Where dewatering is required it shall incorporate standby facilities and shall have been in
operation sufficiently in advance to attain stable groundwater levels before beginning
tunnelling. If, during the course of the work, the shaft face becomes unstable through water
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ingress, it shall be immediately sealed and made safe.
4 Damaged pipes shall be replaced either by pushing through to the end of the line or broken
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out and replaced by pushing up adjacent pipes.
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5 The Contractor shall ensure that oil and lubricant spillage is minimised. Any spillage of oil or
lubricant shall be cleared as soon as is practicable and the inside of the pipes shall be
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cleaned on completion of the pipejacking.
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9.5.2 Tunnelling Shields for Pipejacking
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1 Where considered necessary, the Contractor shall provide and maintain a shield suitable for
excavating in the ground conditions as envisaged by him and in accordance with his chosen
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method of excavation. In determining the type of shield and method of excavation to be

used, the Contractor shall take account of the need to ensure that the face of the excavation
is adequately secured at all times such that ground loss is kept to a minimum and is
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controlled to prevent excessive ground loss. The shield shall be removed on completion of
the tunnelling operation.
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2 Rotating excavating heads fitted to shields shall be capable of rotating clockwise and
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counter-clockwise.
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3 The shield shall be equipped with steering jacks and such beads, ploughs and copy cutters
as may be required for adjusting the alignment of the pipes.
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4 Multiple lubricant injection points shall be provided within the shield in order to provide
immediate ground support when necessary.
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9.6 MICROTUNNELLING
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9.6.1 General
1 Micro-tunnelling shall be defined as a method of installing pipe or casing by jacking the pipe
or casing behind a remotely controlled, laser guided, steerable, guided tunnel boring machine
which fully supports the excavated face with fluid and/or earth pressure balance at all times.
2 Micro-tunnelling pipe is defined as pipe or casing capable of withstanding installation jacking

and any other construction loads in addition to permanent live and dead loads.
3 The method to be employed for micro-tunnelling shall be selected by the Contractor to suit
ground conditions and ground water pressure. The Contractor shall submit a detailed
method statement which shall be approved by the Engineer prior to commencing micro-
tunnelling.
9.6.2 Contractor Responsibilities
1 The Contractor shall carry out, and be responsible for, the detailed design of:
(a) The micro-tunnel;
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(b) All associated works (including shafts, connections, etc.).
2 The design shall be prepared by qualified design engineers or other professionals who
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comply with the criteria stated in the Specifications. The Contractor warrants that he, his
designers and design sub-contractors have the experience and capability necessary for the
design. The Contractor undertakes to ensure that the designers shall be available to attend
discussions with the Engineer at all reasonable times.
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3 The Contractor shall satisfy himself that he has sufficient geotechnical details before
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commencing the detailed design. If available, a copy of existing geotechnical investigation
reports shall be provided to the Contractor. These reports are provided for information only
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and the Contractor is advised to corroborate the details provided and commission any
additional site investigation works he deems to be necessary.
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4 The Contractor shall be responsible for ensuring that he avails himself of all necessary
utilities information, existing and proposed, prior to commencement. Where available, a copy
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of existing utilities information shall be provided by the Engineer. These reports are provided
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for information only and the Contractor shall be responsible for ensuring that the information
collected is the most recent and factual record of existing and proposed services in the
project area. The Contractor shall utilise appropriate equipment and methods to aid him in
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the determination of the line and level of existing utilities apparatus. This may be undertaken
either by the Contractor’s own staff or by specialist sub-contractors.
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5 The Contractor shall be responsible for obtaining all approvals/consents required for the
disposal of excavated material/spoil that is surplus or unsuitable for incorporation in the
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permanent works. The Contractor may propose, subject to the approval of the Engineer,
remedial measures to be taken for the improvement of earthwork arisings, which are not
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suitable in the as-dug condition, for use in the permanent works.

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6 The Contractor shall allow the Engineer full access to real time micro-tunnelling data any time
during construction.
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9.6.3 Safety and Environment

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1 The Contractor shall carry out all works to the requirements outlined in all current appropriate
Regulations, Codes of Practice. The following recognised documents shall form the basis for
guidance and development of the safety plan and site procedures:
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(a) UK Health and Safety at Work Act including the provisions of BS 5228, Parts 1 and 2;
(b) BS 6164: Safety in Tunnelling (Code of Practice);
(c) Guide to Best Practice for the Installation of Pipe-jacks and Micro tunnels.
2 The Contractor shall develop a safety plan to encompass all aspects of safety and
environmental requirements prior to commencement of the work. This plan shall be a
working document and be subject to continuous review throughout the period of the contract.
3 All machinery, including hoists shall be suitable for quiet and efficient operation and shall be
installed and maintained to an acceptable safety standard.
4 A site safety culture shall be instigated on-site prior to work commencing and be developed
throughout the course of construction. The culture will comprise of the use of key
management tools by the site management (and outlined in the site safety plan) in educating
the site operatives in all aspects of best safety practice and awareness in their work. An
induction session shall be given to all operatives and staff irrespective of their discipline and
experience. This should, in particular outline all local requirements relating to the contract,
actions to be taken in event of emergencies, and an overview of the Site and its personnel.
The content of the induction may be varied to suit the recipients. Each operative shall
receive training, together with any appropriate examination or documentation, to ensure he is
completely aware of the requirements of each aspect of his job and the hazards which are
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inherent in its execution.
5 The Contractor shall produce a risk/hazard analysis of the key elements of the pipe-jacking
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operation and utilise the results of the analysis in reducing such risks that remain to a
minimum. Such hazards shall be communicated to workers through induction, tool box talks
and the like.
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6 The Contractor shall develop and implement a plan for immediate underground evacuation in
the event that the presence of toxic/inflammable gas is identified in the excavation. In such
case the Contractor shall identify and take appropriate action to rectify such hazard prior to
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allowing work to recommence.
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7 Appropriate training and certification shall be given to all operators of plant. This shall be
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carried out only by engineering staff competent in the use and hazards associated with the
particular item of plant concerned.
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9.6.4 Performance Requirements

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1 The micro-tunnelling system shall be selected by the Contractor to suit local ground and
groundwater conditions. The Contractor shall submit a detailed method statement for
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approval by the Engineer prior to starting micro-tunnelling work.

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2 Micro-tunnelling operations shall be carried out in a manner that minimizes ground

movement in front of and surrounding the pipeline. Settlement of the ground surface shall be
minimized. Damage to structures and utilities above and in the vicinity of the underground
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operations shall be prevented.

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3 The ground shall be continuously supported in a manner that prevents loss of ground and
maintains the stability of the tunnel face and perimeter at all times.
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4 A full work force shall be maintained on a continuous basis (24 hours per day) during any
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emergency or work stoppage that could endanger the tunnel excavation, sub-surface
infrastructure and surface facilities.
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5 Dust, noxious gasses or other atmospheric impurities shall be actively controlled in

accordance with the relevant Qatar occupational health and safety legislation. Approved
instrumentation for monitoring air quality in work areas and pipelines accessed by personnel
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shall be provided. This environmental control and associated procedures to be followed in

monitoring shall be fully documented in the Contractor’s Safety Plan.
6 All micro-tunnelling and underground construction work shall be performed in accordance

with the relevant Qatar occupational health and safety legislation and the approved
Contractor’s Safety Plan. This Plan shall include safe procedures to mitigate risks associated
with the work, including identification and logging of any and all visitors into and out of the
underground works and prevention of unauthorized entry. Safe procedures shall also be
established for personnel entering the tunnel to carry out maintenance or for other purposes.
9.6.5 Micro-tunnel Design Elements
1 Tunnel Pipe Design
(a) The watertight lining pipe shall be installed by single pass pipe jacking using a remote
controlled tunnelling operation to the alignments and grades shown on the drawings.
Remote controlled tunnelling operations apply to trenchless pipe installation by micro-
tunnelling where the carrier pipe is installed directly behind the tunnelling machine and
the machine provides support to the excavation face at all times.
(b) All jacking pipes, including special designs, shall be sufficiently reinforced with steel to
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withstand all stresses induced by handling, jacking, earth and water pressures and all
working loads at the depths at which they are to be used without cracking, spalling or
distortion. A load factor of not less than 1.5 shall be used in the calculations to
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determine the strength of the pipes required. The clear cover to any steel
reinforcement shall not be less than nominal 50 mm. The pipes are designed and
calculated in according ATV 161 (Technical Standard of pipe jacking).
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(c) The strength of the pipes shall be tested by a three edge bearing test. When
subjected to the design load in such a test, the maximum crack developed on the pipe
shall not exceed 0.25 mm. If this test not possible an equivalent quality control and
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security system has to be developed.
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(d) All pipes shall be manufactured by a supplier approved by the Engineer. The process
of manufacture may be by centrifugal or vertical casting subject to submission and
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approval by the Engineer. All pipes shall be cast with a minimum of 3 grout holes
equally spaced around the pipe wall. A steel threaded insert (¾ to 1 BSP minimum
dimension) shall be cast in each hole. All pipes shall be of spigot and socket design
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with an integral steel collar cast on the socket or trailing end. The collar shall be
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suitably and securely fixed to the reinforcing cage of the pipe prior to the pipe being
cast. Each pipe shall have a 75 mm dia lifting hole or lifting anchor cast in the top
centre to facilitate a lifting device. All pipes shall have their date of manufacture clearly
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and indelibly marked on them. All pipes shall be fully cured and have reached the
designed concrete strength prior to delivery.
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(e) The Contractor shall submit full details of his proposals for the pipes, giving detailed
drawings showing sizes, reinforcement and jointing arrangements, all cast in items and
concrete design including specifications for all component materials. A full set of
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design calculations including the parameters adopted for the design shall also be
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submitted.
(f) The name of the manufacturer, place of manufacture and manufacturing process shall
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be identified at an early stage and provision made for inspection of such facilities by
the Engineer for his approval.
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(g) The jacking equipment including any required intermediate jacking stations shall have
a capacity of not less than 20 per cent greater than the calculated theoretical
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maximum jacking load.

(h) The design of the tunnel shall take into account the required life span, the proposed
use, the ground conditions, the sequence and timing of construction and the local
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existence of adjacent structures. Relaxation of stresses in front of boring machine and

excavation, installation and water-tightness of lining pipe should be considered. The
required life span is 100 years. 100-year durability design shall meet the requirements
of BS 8110.
(i) Numerical methods shall be used to evaluate the loading on the lining pipe. Results of
the numerical calculations shall be used to assess surface settlements. The
Contractor shall specify, justify and explain the model he intends to use. The
Contractor shall also submit two licensed English versions of the software including all
manuals, to the Engineer.
(j) The Contractor shall be solely responsible for the accuracy of the numerical model and
the assumptions necessary to fully simulate the anticipated ground and the tunnel
excavation within it, the installation of any support measures and the construction of
the permanent tunnel lining system. The Contractor shall provide in his Design
Submission numerical simulations which are applicable to and reflect the work and
construction stages proposed by him. State of the art modelling techniques, material
properties, simulation procedures and material definition, shall be applied. In addition
the Contractor shall at least consider the requirements as outlined below for the
modelling process:
2 Tunnel Access Shaft
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(a) The positions of the micro-tunnel shafts and tunnel are shown on the Contract
Drawings. The Contractor may suggest alternative positions to suit his equipment and
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works programme. The final depth and position of the shafts and tunnel however shall
be subject to the approval of the Engineer.
(b) The working shaft shall be designed to withstand the force applied by the main jacking
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station and of adequate dimensions to fully cater for the underground installation of all
necessary pipe-jacking equipment. This will include the jacking frame and thrust ring
assembly, slurry pumping equipment, electrical isolation box and guidance system.
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Consideration must also be given to safe access and working space for the pit bottom
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crew. The design of the shaft base shall incorporate the requirements of a thrust block
for the jacking frame to bear upon and a tunnel launching eye and sealing ring through
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which the TBM is launched. The design of these structures will depend on the type of
ground and jacking pressures envisaged. They are normally considered to be
temporary structures, being removed on completion of the drive, but consideration may
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be given to incorporating them in the permanent works wherever possible.
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(c) Requirements for launching the TBM assembly, which may comprise multiple units of
varying length, shall also be taken into consideration when deciding upon the overall
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size of the shaft base.

(d) Micro-tunnel shafts shall be placed at main road intersections to take drainage from
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the surrounding areas.

(e) Micro-tunnel shafts shall be built to Employer’s standards and requirements. The
Contractor may propose alternative designs subject to the approval of the Engineer.
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(f) Shaft openings shall be located within the central reservation or footway areas. No
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openings shall be accepted within the highway carriageway.

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(g) The design of the tunnel shafts shall take due account of the following:
(i) Need to provide a structurally sound and stable reinforced concrete shaft wall
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and superstructure that shall comply with all relevant BSI standards. Design
calculations and materials shall be submitted for approval to the Engineer prior
to any construction work being undertaken.
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(ii) All shafts shall be watertight.

(iii) All shafts for sewerage applications shall be full lined internally with GRP in
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accordance with Part 4, Clause 4.4.1.

(iv) All shafts for surface water / ground water applications shall have a combination
of GRP lining and epoxy protective coating internally in accordance with Part 4,
Clause 4.4.2. .
(v) Where practical, the underside of the base slab and external faces of the walls
shall be protected by a membrane tanking system. Where this is not possible,
the Contractor shall propose a protection system for approval by the Engineer.
(vi) All ladders, platforms and handrails, where shown on the Contract Drawings,
shall be to QCS Section 8, Part 6, Clauses 6.4.1 to 6.4.7. Platforms shall be
provided at maximum distances of 6 metres and shall be positioned to allow
maintenance equipment to be lowered unhindered to the base of the shaft.

Ladders shall terminate at platforms and be staggered between platforms.
(vii) Down-pipes shall be secured by stainless steel brackets to the inside of walls.
9.6.6 Design Checking
1 All drawings and calculations intended for incorporation into the design package shall be
checked by an approved Independent Checker. Evidence of the extent and scope of
checking carried out on each set or subset of calculations shall be provided either in the form
of parallel calculations or by marking up the calculation sheets or by providing a summary on
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the cover sheet.
2 All drawings shall be checked with due consideration for the following:
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(a) completeness;
(b) compliance with the relevant requirements of the Contract Documents;
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(c) consistency between calculations, schedules, reports, drawings, specifications;
(d) compliance with standards, codes, regulations and statutory requirements;
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(e) dimensional accuracy and presentation.
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With his approval the Independent Checker confirms that the relevant documents are in
compliance with the Employer’s requirements, relevant local and international standards and
designed correctly.
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9.6.7 Finite Element (FE) and Finite Difference (FD) Models

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1 A numerical analysis shall be carried out and fulfil the following geometrical requirements:
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(a) Notwithstanding the requirements as listed below the mesh layout shall be such that
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numerical accuracy is guaranteed. If required, the Contractor shall perform sensitivity

studies with different levels of mesh refinement.
(b) Width of mesh shall extend at least two tunnel diameters beyond the limits of the
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tunnel lining.
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(c) The model used for the design at the ground sections of the tunnel shall be capable of
considering the joint system and joint properties of the ground strata, by either explicitly
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modelling joint systems or applying suitable models with equivalent properties.

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2 Element size around excavation contours shall not be larger than those elements that
correspond to an angle of 10 degrees along the arch. Infinite elements shall be used along
the border of the mesh or a suitably large mesh shall be proposed so that the influence of
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boundary of mesh is negligible for FE models: The practical limit of the aspect ratio of zones
should be kept to approximately 1:4 or less in order to achieve reasonable solution accuracy.
The practical limit for FD models of the aspect ratio of zones should be kept to approximately
1:1 or less in order to achieve reasonable solution accuracy.
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3 Each computation shall be accompanied by a report that shall at least include a description
and interpretation of:
(a) definition of the mesh;

(b) selection of design sections;
(c) definition of geological strata;
(d) selected input parameters;
(e) material models used;
(f) results including surface settlements and expected deformations in the tunnel;
(g) dimensioning of the tunnel lining.
9.6.8 Verification of Results
1 Numerical calculations for the design of the lining shall be verified using different analytical
methods.
9.6.9 Design Parameters for the Calculations
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1 Parameters required for the design and not defined in this document shall be established by
the Contractor. All details on these parameters shall be provided by the Contractor in his
Design Basis Report subject to the consent of the Engineer.
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2 The results of site investigations carried out are to be summarised in the Data Reports and
the Contractor shall conduct supplementary site investigations within the project area as
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designated and/or where considered appropriate. The interpretation of all site investigation
data, including the interpretation of the Data Reports and of the bore logs shall be the
responsibility of the Contractor. The Contractor shall justify and explain the derivation of all
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his geotechnical parameters in his geotechnical interpretative report. The geotechnical
parameters used for the design require the consent of the Engineer. The worst credible
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ground parameters as identified in the site investigation data shall be used to check the
micro-tunnel lining (at the ultimate limit state).
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9.6.10 Design Loadings
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1 The Contractor shall include for the following loads in his calculation of the stresses and
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strains induced in the installed pipeline:

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(a) Ground/Rock Loads;

(b) Water Loads: Groundwater levels with sufficient safety margins for the design shall be
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determined from groundwater observations. The design calculations shall be carried

out both for an upper bound and a lower bound of the ground water level subject to the
consent of the Engineer;
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(c) Live Loads: For underground structures under a roadway, a live load as defined in BS
5400, Part 2 for highway bridges considering type HA loading combined with 45 units
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HB loading shall be allowed for in the design;

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(d) Surcharge Loads: For all underground structures and in locations where live loads as
specified above do not apply, a surcharge load of 22.5 kN/m² applied at ground level
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shall be allowed for in the design;

(e) All other loads.
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2 The Contractor shall take into account any other loading criteria which may be applicable to
achieve the full performance of the micro-tunnel, including water pressures under operational
conditions within the lined tunnel.
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3 In addition to the design sections as defined above the Contractor shall carry out case
studies of all relevant and possible combinations of geological, hydrogeological and
geometrical conditions as necessary for his design and construction. The Contractor shall
also provide calculations in accordance with the soil /rock classification proposed by the
Contractor and based on the Contractor’s geotechnical interpretation. The Contractor’s
calculations shall cover all possible geotechnical conditions anticipated over the entire tunnel
length. Notwithstanding the calculations as requested above, the Contractor shall consider
within his design submissions one numerical simulation of the tunnel construction of at least
every 400 m of the bored tunnel section. Within the Preliminary Design Submission the
Contractor shall propose these calculation sections which shall be subject to the consent of
the Engineer.
9.6.11 Design Submissions
1 The Contractor shall submit his proposed detailed design report to the Engineer for approval,
not less than four weeks prior to his intended construction start date for this element of work,
or as specified by the Engineer. The submission should include, but not be limited to, the
following :
(a) Summary of all subjects addressed in the design stages;

(b) Summary of the design criteria adopted in the design stages;
(c) Final hydraulic model for overall drainage system including all input and output data;
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(d) Final hydraulic design and calculations for overall drainage system including
connections;
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(e) Final hydraulic design and calculations for the temporary pumping station if required.
2 For the purpose of obtaining all necessary approvals on completion of the detail design
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stage, the Contractor shall submit to the Engineer the following:
(a) 4 no. complete sets of detail drawings-paper prints (A1) to include:
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(i) The modified positive surface water drainage system and micro-tunnel plans at
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1:1000 scale based on survey sheets and incorporating coordinate grid,
proposed sewers connections, access and maintenance shafts, invert, cover
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and ground levels. Key plan of the proposed system plans including coordinate
grid, contract area, sewer connections, main building and road/street names,
and layout plan of the temporary pumping station sites at 1:100 or 1:50 scale if
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required.
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Sections of micro-tunnel and the modified positive surface water drainage system at
1:1000 horizontal and 1:100 vertical scales. Sections are to be related to each the
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system plan and include chainages, access and maintenance shafts number, invert,
cover and ground level, tunnel diameter, gradient, terrain crossed, major service
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crossings and any connecting branch sewer details.

Standard drawings for the modified positive surface water drainage system, micro-
tunnel cross section, access and maintenance shafts and miscellaneous details to
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appropriate scales based on Employer’s standards.

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(b) 4 no. complete sets of the detailed construction specification;

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(c) 4 no. Bills of Quantities, containing the principal items;

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(d) The submittal of the detail design for approval shall also be accompanied by 4 copies
of a comprehensive “Engineering Report” including the design calculations, which will
detail revisions and amendments to the design subsequent to the approvals given for
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design. The report shall include copies of the comments made on the design and
corresponding actions taken;
(e) Drawings, designs, documents and reports submitted for approval will not be accepted
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if there is no evidence of internal, qualified, checking; or if the quality of the contents of

the Drawings and documents clearly indicate that they have not been checked
thoroughly;
(f) Partial submittals will not be accepted.
If significant changes are required to the above original document submissions, the
Contractor shall re-submit to the Engineer.
9.6.12 Certification Procedure
1 The entire design of the Bored and any Cut and Cover Tunnels (layout design, structural
design and geotechnical design) shall be checked by the Accredited Checker. On
completion of the design and check the respective certificates shall be submitted to the
Engineer in accordance with the UK DMRB BD 2/02.
2 The Contractor shall provide a certificate of assurance from a reputable TBM manufacturer
or refurbisher to warranty that the proposed TBM is fit for purpose to carry out the intended
works.
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3 At least four weeks before the commencement of any tunnel excavation works, the
Contractor shall submit to the Engineer test certificates concerning all material properties and
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characteristics as defined in the relevant sections herein and/or used for tunnel design
purposes from an independent and acknowledged source.
9.6.13 Contractor’s Documents
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1 The Contractor’s Documents shall comprise, but not be limited to the following:
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(a) Safety Procedure Manual (Project Specific Safety Plan);
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(b) Risk mitigation plan;
(c) Contingency plan;
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(d) Pre-construction inspection reports of adjacent properties and utilities;
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(e) List of drilling team (Names, qualifications, experience, training, etc.) and management
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control.
2 Full details of the micro-tunnelling system shall be supplied with the above submittals,
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including:
(a) Type(s), number(s) and model reference of proposed micro-tunnelling system.

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If not from single source, detail main elements of the system.

(b) Written confirmation from manufacturer (with company seal) that the machine
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configuration is suitable for the external diameter of pipe proposed.

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(c) Cutter face details, including tooling and face port opening dimensions.
(d) System of alignment control and steering control and activation.
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(e) Full details and justification for excavation and spoil disposal method(s).
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(f) Hydraulic jacking system maximum capacity and method of limiting to maximum
jacking pipe capacity.
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(g) Details of any intermediate jacking stations.

(h) Electrical system and on-site power supply.
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(i) Proposed communication system between the MTBM (Micro-Tunnel Boring Machine)
and operating personnel on the surface.
3 Full and comprehensive details of the procedures and resources that will be used to perform
the work shall be provided, including;
(a) Machine launch and reception;

(b) Pipe handling and connections;
(c) Supplementary alignment surveying;
(d) Excavation and spoil disposal;
(e) Closure of any intermediate jacking stations;
(f) Emergency procedures;

(g) Ventilation of tunnel, including gas monitoring.
(h) All materials, including slurry, lubricants;
(i) Location of approved spoil disposal facility;
(j) Drawings showing layout, temporary equipment locations and complete jacking set-up
in typical jacking shaft.
4 Daily logs shall be used to record the micro-tunnelling work and any associated delays. The
log shall be submitted to the Engineer for record purposes on a weekly basis. The basis of
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the log shall be the electronic data recorder that operates with the micro-tunnelling system.
The log shall include:
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(a) MTBM alignment deviation data and applied jacking load shall be recorded at intervals;
(b) Alignment deviation shall not exceed 0.3 m in 5 minutes;
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(c) The commencement and completion of jacking of each pipe section;
(d) The operating pressure if pressure balanced system is used;
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(e) Quantities of lubricant injected;
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(f) Air quality monitoring results;
(g) Unusual events.
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9.6.14 Construction Responsibilities
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1 During construction, the Contractor shall be responsible for:

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(a) Providing a temporary and secured drainage system for the Works (N.B. restricted
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access, safe and dry working environment, etc.);

(b) Taking all necessary precautions to protect the tunnel and/or adjacent properties from
flooding (e.g. groundwater may be problematic in the area);
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(c) Provision of a temporary wall, if required, to enable the executed tunnel section to
serve as temporary storage.
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2 The Contractor shall provide temporary pumping facilities to the extent required to avoid
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delays to the construction programme and quality of the work. The Contractor shall also
indicate any EFA sites (Emergency Flood Area) if required for flood alleviation works during
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the construction works and confirm the availability of the land. The Contractor shall be
responsible for the fencing, safety and security of any temporary EFA areas. Any fuel and/or
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power sources shall be provided as appropriate. All facilities/connections in this respect shall
comply with standard regulations regarding their storage and/or use.
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3 The Contractor however shall be responsible at his cost for providing temporary submersible
pumps to evacuate any flooded tunnel sections and discharge to an acceptable outfall point.
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9.6.15 Quality Assurance/Control
1 All pipes delivered to site shall be the subject of inspection and approval by the Engineer
before they can be incorporated in the Works. Any and all rejected pipes shall be immediately
removed from site and replaced with pipes acceptable to the Engineer. Pipes and pipe
gaskets shall be stored or stacked on-site in accordance with the manufacturer’s
recommendations.
2 Every jacking shift shall be supervised by at least one person with previous experience of
micro-tunnelling work. Operators of the micro-tunnelling system shall have prior knowledge
and ability in its proper operation and shall run test the system after set-up and before
starting the drive. The Contractor shall follow manufacturers’ instructions when operating the
complete system and operational manuals shall be available to site operational personnel at
all times.
3 The installed pipeline shall be subject to visual inspection. Visible leaks (flowing or dripping
water) in pipes, pipe joints, manholes and structures shall be repaired even if leakage test
requirements are satisfied.
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9.6.16 Materials
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1 Pipe repair materials shall be supplied by the pipe manufacturer as suitable for the intended
purpose and applied strictly in accordance with the pipe manufacturer’s instructions. Water
used for lubricant or grout shall be of neutral pH and shall be clean, fresh and free from oil,
organic or other deleterious matter. Polymers shall be non-toxic and grout for filling voids
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outside the installed micro-tunnel pipeline shall be designed by the Contractor and submitted
for approval. The pipe material shall be reinforced concrete (RC) or GRP subject to the
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2 The Contractor shall also submit a sample of the pipe wall section, joint band and gasket
seal. This wall section shall be completely fitted with the proposed grout bush and flush
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fitting plug to be watertight.
3 The Contractor shall obtain the pipe manufacturer’s warranty that the pipe conforms to the
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specifications and shall be free from defects in materials and workmanship.

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9.6.17 Temporary Works

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1 The Contractor shall develop his temporary works design taking into account all site
constraints identified elsewhere in the Contract Documents. The Contractor shall provide
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clear method statements detailing all stages of the temporary works including supporting
calculations for the temporary works. These method statements shall be issued to the
Engineer before works can commence. Calculations shall be included where relevant, e.g.
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as part of settlement checks on adjacent structures. A “Detailed Safety Plan” identifying

hazards and mitigating measures shall also be included in the Temporary Works Method
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Statements.
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9.6.18 Construction Preparation

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1 The Contractor shall be responsible for:
(a) the means and methods of micro-tunnelling and pipe jacking operations and shall be
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solely responsible for and shall ensure the safety of the work, his site personnel, the
public and adjacent property (public and private);
(b) maintenance of clean working conditions at all locations at all times;
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(c) control and implementation of safety precautions for personnel entering pipeline;
(d) organizing equipment in all areas to ensure safe operation at all times;
(e) providing safeguards to prevent leakage of fuel or lubrication oils from micro-tunnelling
system equipment. Hydraulic oils used by the Contractor’s plant shall be bio-
degradable and non-flammable.
9.6.19 Pipeline Installation
1 The pipeline shall be placed within 50 mm of the vertical and 200 mm of the horizontal
alignment shown on the Drawings. Steering corrections shall be made to the pipeline so that
the joint to joint angle of any two adjacent pipes does not exceed 0.5 degrees. The
Contractor shall submit daily records of deviations.
2 Each section of pipe shall be jacked forward as the excavation progresses in such a manner
that complete and adequate ground support is provided at all times and such that joints
maintain their integrity and the pipe train continuity is maintained.
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3 The Contractor shall ensure that jacking loads do not exceed the manufacturer’s safe jacking
capacity by effective management of the pipe jacking alignment and pipe lubrication controls
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(intermediate jacking stations).
4 No damaged pipes shall be permitted to be used in the permanent works. Pipes damaged in
the casting and handling process in the factory shall not be permitted on-site. Repairs to cast
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pipes, either in the factory or on-site shall be confined to minor cosmetic repairs only. All
repairs shall be subject to the approval of the Engineer and carried out to an approved
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procedure. Any pipes identified as being unfit for use in the tunnel shall either be removed
from site and destroyed or clearly marked and quarantined for later inspection and possible
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repair.
5
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A proprietary seal of rubber or EPDM shall be incorporated in each pipe joint, including joints
between pipes and inter-jacks / TBM. The design of the seal shall be commensurate with the
detailing of the pipe joint. Seals may be fitted either at the place of manufacture or on-site
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prior to placing of the pipe below ground. In either case the seals shall be fitted in accordance
with the manufacturer’s instructions. Seals shall be inspected for damage by the surface
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crew immediately prior to pipe use and any damaged seals replaced. Pipe seals shall be
suitably lubricated with a soap solution or other such compound in the pit bottom immediately
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prior to closing the joint with the jacking frame.

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6 A minimum of 30 mm thick Medium Density Fibreboard (MDF) packer shall be fitted to the
socket face of each pipe prior to the pipe being used in the tunnel. The packer, comprising
several segments to form the 360% annulus, shall be firmly glued to the socket end and in
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such manner as to be 25 mm inset from the intrados of the pipe. These packers may be
fitted on either at the factory or on-site, however it should be noted that in wet weather
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conditions suitable protection may be required in cases of lengthy exposures.

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7 Pipes shall only be lifted on-site using the cast in lifting hole or lifting anchor and a purpose
made lifting device. Such device shall be fully tested and carry relevant certification. Pipes
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shall be stored in an orderly fashion in a designated area, not more than two pipes high and
on purpose made timber supports.
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8 Pipes shall be power lowered by crane or gantry down the working shaft and set on a
purpose made cradle comprising the base of the jacking frame assembly. The cradle shall
have been set true to line and level prior to commencement of the jacking and secured to the
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shaft bottom. The thrust wall assembly behind the jacking frame shall also be set at right
angles to the line of drive to ensure that no misalignment occurs at the pipe joint on closure.
The lifting device shall be removed from the pipe prior to the joint being closed and jacking of
the pipeline recommenced. The lifting hole shall be sealed with a precast concrete plug and
rapid setting mortar prior to the hole location passing through the eye seal. Jacking of the
pipeline shall be carried out in such manner as to limit any deflection at a joint to the
manufacturer's recommended maximum. Pipe loadings shall normally be limited to 50% of
the design load (or similar as agreed) whereupon an inter-jack assembly shall be installed.
9 On completion of a drive the line shall be fully inspected for damage or leaking joints. The
Contractor shall propose remedial works in such cases. Holes used for injection of lubricants
shall be filled with an approved mortar to a smooth finish at the intrados of the pipe.
9.6.20 Construction Execution
1 All excavation works shall be properly set out to the line, level, curve or slope required within
accepted tolerances. Survey stations, centre lines, bench marks and grade lines shall be
clearly marked in paint on the tunnel walls. Chainages at 10 metre intervals shall also be
clearly marked by appropriate permanent means.
2 Internal tunnel marking shall be done prior to jacking any “lining” pipes. This method can be
used to mark the exact location of any problem areas during the jacking operation.
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3 The Contractor shall establish and maintain reference control lines and grades for the Works,
which shall be used to exactly locate the pipeline and structures. The primary control for the
micro-tunnelling system shall be checked at least once per week or not more than 60 metre
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intervals of constructed pipeline.
9.6.21 Working in Compressed Air
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1 Provisions shall be made on the tunnelling machine to facilitate entry into the face of the
machine under compressed air for inspections and maintenance. These provisions shall
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comply in all respects with all relevant statutory regulations governing work in compressed
air. The airlocks and other equipment fitted to the machine shall comply with the
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requirements of CENprEN12110.
2
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All equipment and personnel necessary to perform such interventions for inspection or
maintenance shall be available throughout the pipe-jacking operations.
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3 The Contractor shall submit details of the compressed air installation for the Engineer’s
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approval, along with details of the qualification and previous experience of lock attendants,
medical lock attendants, compressor attendants and supervisory staff.
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4 In highly permeable ground where air losses might be excessive, arrangements shall be
made to inject thick bentonite slurry into the face prior to an intervention to form a cake on
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the exposed face in order to limit air loss.
5 Air compressors shall have a standby capacity of at least 50% and be powered by an
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independent power source.

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6 All essential parts of the compressed air system, including pipelines carrying compressed air
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to the face, shall be duplicated. All pipework, valves, gauges, etc. must be protected from
impact damage. Where flexible hoses are used to carry the compressed air through the pit
bottom jacking arrangement they shall also be protected from entrapment. In the event of
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failure of one part of the system it should be possible to isolate that part without interrupting
the air supply.
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7 A safety valve shall be fitted to free air side of the pressure bulkhead of the tunnelling
machine. This safety valve shall be set to relieve at marginally above the working pressure
and shall be of adequate size to match the installed capacity of the air compressors. Prior to
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any work in compressed air the system should be tested to working pressure.
8 Any airlock fitted to the tunnelling machine shall be at least 1.5 meters diameter. The air lock
should be designed as a pressure vessel, subjected to a hydraulic test and issued with an
appropriate test certificate. Air lock doors should be at least 500 millimetres by 400
millimetres. Doors should normally be kept closed by the air pressure but the door opening
to the front of the tunnelling machine should also be able to be locked shut whilst persons are
being decompressed in the lock. The airlock should be comprised of two chambers to allow
access into the working chamber in case of emergency. For use at pressures above one bar
the lock should be fitted with seating for the persons being decompressed. Where the
working pressure is above 0.7 bar a medical lock shall be provided which shall be manned by
a medical lock attendant whenever work in compressed air is in progress and for twenty four
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hours afterwards. If necessary the quality of the compressed air supplied to the working
chamber shall be improved by coolers and filters to ensure compliance with the specified
requirements. The supply of compressed air to the working chamber shall be sufficient to
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ensure that the level of any contaminant shall not exceed 10% of the short term exposure
level when measured at atmospheric pressure. Air quality should be monitored at least once
per day.
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9 The Contractor shall appoint a registered medical practitioner experienced in compressed air
work to advise on decompression methods to be adopted and on all other aspects of health
relating to the work in compressed air. All employees will be medically examined prior to
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working in compressed air. Records will kept of all medical examinations and details of each
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compressed air exposure including working pressure, working time, decompression
procedures, etc. No person shall be allowed to work in compressed air if the Contractor has
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reason to suspect that person is under the influence of drink or drugs such that his capacity
is impaired. No one shall be allowed to enter the compressed air working chamber alone.
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10 An experienced lock attendant shall be on duty at the free air side of the air lock at all times
when there are persons in the compressed air working chamber. All valves gauges and
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controls at the lock attendant’s station shall be clearly marked with their function and method
of operation.
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11 Smoking shall be banned in compressed air and no person shall take smoking materials into
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compressed air. As far as is practicable no combustible material shall be taken into the air
locks and or the working chamber. The use of burning or welding equipment should be
strictly limited and shall be subject to a permit to work system. Fire extinguishers shall be
provided in the air locks and the working chamber whenever work in compressed air is in
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progress.
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9.6.22 Ground Pre-treatment

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1 Pre-treatment of the ground, where applicable, shall be applied in advance of the tunnel
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excavation to provide sufficient stability of the excavated area. Execution of such works shall
not commence before consent has been given to the design of such works by the Engineer.
The surface settlement monitoring shall be installed, initialised and baselined prior to any
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ground modification work.
9.6.23 Drainage During Construction

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1 The Contractor shall supply, install, operate and maintain sufficient pumps and pipe work to
control and remove water from any part of the underground works. Standing water shall not
be allowed. The capacity of pumps installed where required, including at launch/reception
pits, shall always be at least twice the normal volume of the inflow of water plus the volume of
flushing water if drilling equipment is used. The minimum capacity of the pumps shall be 20
l/s.
2 The Contractor shall store or immediately have available standby pumps in good working
conditions of the same capacity. This equipment shall be maintained properly and tested
frequently.
3 The Contractor shall provide settlement tanks or other decontamination facilities before the
water is discharged. The Contractor shall submit his design for these facilities as part of his
method statement. The Contractor shall remove all accumulated slurry, silt or other debris
from the Works on an ongoing basis.
9.6.24 Disposal of Tunnel Seepage and Waste Water
1 Tunnel seepage and wastewater arising from the Works shall be collected and discharged
via a settlement tank. Seepage and wastewater shall not be discharged into the public
drainage system unless it meets the standards listed below. Where necessary, the water
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shall be treated to achieve these standards.
2 The Contractor shall comply with BS 6031:1981 Code of Practice for Earthworks or
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equivalent, regarding the general control of site drainage and the requirements of the
Relevant Authority. The Contractor shall ensure that water which may have come into contact
with contaminated material shall be disposed of in an appropriate manner. The Contractor
shall have to apply for consents and approvals as follows:
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(a) obtain and complete standard “permit application form” for proposed discharge into a
PWA system.
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(b) before any discharges can be permitted into a PWA pipeline, written approval shall be
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obtained from the relevant department of the PWA. Failure to obtain the permit can
result in immediate closure of the Works. M
3 The Contractor shall make provisions that all hazardous substances including oil drums or
containers on-site are controlled in accordance with the relevant legislation and are properly
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stored so that no oil or their contaminants are allowed to reach watercourses or groundwater.
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9.6.25 Testing
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1 The Contractor shall provide all apparatus, assistance, documents and other information,
electricity, equipment, fuel, consumable, instruments, labour, materials, and suitably qualified
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and experienced staff, as are necessary to carry out the specified tests efficiently. The
Contractor shall agree, with the Engineer, the time and place for the specified testing of any
plant, materials and other parts of the Works.
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2 The Engineer may vary the locations of details of specified tests, or instruct the Contractor to
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carry out additional tests. If these varied or additional tests show that the tested Materials or
workmanship is not in accordance with the Contract, the cost of carrying out this Variation
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shall be borne by the Contractor, notwithstanding other provisions of the Contract.

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3 The Contractor shall promptly forward to the Engineer duly certified reports of the tests.
When the specified tests have been passed, the Engineer shall endorse the Contractor’s test
certificate, or issue a certificate to him to that effect.
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9.6.26 Grouting
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1 As soon as each section of pipeline has been installed, its periphery shall be grouted using a
cement based grout with a minimum 48 hour compressive strength of 345 kPa (50psi) and
minimum 28 days compressive strength of 1380 kPa (200psi). Every effort shall be made by
the Contractor to place the grout even when it is known that the periphery contains polymer
or other lubricant and shall demonstrate that grout is not being taken before the grouting
operation is terminated.
2 The grouting pressure shall be sufficient to move the grout to fill the annulus along the pipe
but shall not be greater at the injection nozzle than the pressure limit set by the pipe
manufacturer. The injection points shall be placed at not more than 6 metre intervals along
the pipeline. Grouting shall be carried out around pipelines at launch and reception shafts as
soon as the pipeline is placed at these locations to prevent water and soil from entering the
shafts. Additional grouting shall be carried out at the Contractor’s expense, if required to
ensure that the joints are watertight.
3 The micro-tunnel shall be adequately lit and ventilated for safe access, egress and for
working. If open flames are to be used where combustible gasses may enter the air, tests for
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combustible gas shall be conducted continuously during the work. The tunnel workers shall
carry a gas meter that automatically records the level of combustible gas. Particular care
shall be taken that pipe repairs are carried out in accordance with approved ventilation and
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safety procedures.
4 Infiltration Acceptance Test of the installed pipe, which shall be witnessed by the Engineer,
shall be in accordance with ASTM C969. The internal inspection of the completed pipeline
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shall be the subject of approval by the Engineer.
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9.6.27 Surface and Building Settlement Monitoring
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1 The Contractor shall submit, for the consent of the Engineer, the detailed proposal for
positioning of ground and building monitoring points and other instruments and the frequency
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of the measurements. Excavation works shall not start until the consent of the Engineer to
that submission has been obtained. During construction the Contractor shall review
monitoring frequencies depending on settlement trends, the extent of construction activity in
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an area and the behaviour of the structures.

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2 The monitoring data shall be copied to the Engineer on the same day that the readings are
taken, followed by hard copies with analysis within 24 hours. In addition to carrying out all the
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normal surveying requirements for carrying out a pipe-jack the Contractor shall set-up
surface settlement monitoring points at suitable intervals along the projected pipeline. The
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spacing of such points may be as close as 10 metres in sensitive areas however may vary
according to the depth and location of the jack.
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3 In addition to monitoring over the centre line of the drive readings shall be taken at suitable
lateral distances to the centreline at each monitoring chainage. In roads these cross sections
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shall extend the full width of the road corridor.

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4 Settlement monitoring points shall also be installed at the corner of each building or structure
within a recognised distance from the tunnel centreline. The distance shall normally be
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equivalent to the depth to invert of the proposed pipeline with a minimum of 20 metres.
5 A full record of existing ground and structure levels shall be taken and agreed prior to
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commencement of pipe-jacking operations.
6 A photographic record of existing damage and faults to all adjacent surface structures shall
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be made by the Contractor and agreed prior to commencement of pipe-jacking operations.
7 During the jacking operation between any two shafts the Contractor shall survey the levels of
the appropriate monitoring points on a daily basis.
8 Monitoring shall be carried out on any particular section of points when the tunnel face is
within 20-50 metres of that section dependent on the tunnel depth and ground conditions.
Monitoring shall continue at each section until the tunnel drive has been completed or in the
case of excessive settlement until the settlement has ceased or the rate of settlement
becomes acceptable.
9 If during jacking operations the actual movement of the ground reaches 90% of the predicted
value the Contractor shall immediately review his predictions and if appropriate revise his
operational procedures accordingly. Where such movement occurs suddenly and adjacent
to the tunnel face the Contractor shall not proceed with the jacking operation until a revised
method has been agreed with the Engineer.
9.6.28 Contractor’s Obligations
1 The Contractor shall carry out the Tests on Completion in accordance with this Clause after
providing the “As-Built” documents for the part to be tested.
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2 Unless otherwise stated in the Particular Conditions, the Tests on Completion shall be carried
out in the following sequence:
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(a) Pre-commissioning tests per stage, which shall include the appropriate inspections
and pressure tests to demonstrate that each item of the stage is acceptable and that
the Works can safely proceed to the next stage
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(b) Commissioning tests, which shall include the specified operational tests to
demonstrate that the Works or Section can be operated safely and as specified, under
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all available operating conditions.
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3 For all tests described in sub-paragraph (a) and (b) the pipe and joints shall be considered
watertight if water infiltration is so low that it can only be detected as damp patches without
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flowing or dripping water. Likewise, the tests described in sub-paragraph (a) and (b) shall be
used to confirm that the pipeline remains equally watertight throughout the leak testing.
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4 As soon as the Works, or a Section, have passed each of the Tests on Completion described
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in sub-paragraph (a) and/or (b), the Contractor shall submit a certified report of the results of
these tests to the Engineer.
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9.6.29 Microtunnelling Machine

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1 A remote control tunnelling machine shall be used and it shall include a closed circuit
television (CCTV) camera which transmits a picture of the laser beam on the target together
with other machine information (such as jacking force, face pressure, length, roll, pitch,
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steering attitude, temperature valves open or closed) to a microprocessor console on the

surface from where the system is operated.
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2 The tunnelling machine shall be steerable, incorporating hydraulic rams to move the
articulated cutting head. The line and level control shall be achieved by a laser beam
transmitted from the jacking shaft to a target mounted in the tunnelling machine
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3 The design of the tunnelling machine shall ensure no rotation or rolling during installation.
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4 The tunnelling machine shall be capable of operating under groundwater conditions where
encountered. The hydrostatic balance shall be not less than 3 m head of water.
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9.7 THRUST SYSTEM

1 The thrust system shall distribute the force to the pipes through a thrust ring and packing.
The jacks shall be capable of applying the thrust symmetrically to the thrust ring. Intermediate
jacking stations may be used at the discretion of the Contractor where frictional resistance or
obstructions result in unacceptable thrust forces.
2 A purpose made compressible packer of hard board or other approved material shall be
included between the thrusting surfaces. Pushing blocks shall not be in direct contact with
the pipe or preformed unit, which shall be protected by means of a steel ring, template or
other approved method. Damaged pushing blocks shall not be used.
3 Spacer blocks, if used, shall be true and free of distortion.
4 Thrust rings shall be free from distortions and sufficiently stiff so as to transfer the load from
the jacks uniformly to the packing.
5 Except at the shield, each group of jacks shall be interconnected hydraulically to ensure that
the load is evenly distributed to the thrust ring. Each jack shall incorporate a load cell.
6 At the rig and at intermediate station, automatic thrust recording equipment monitoring load
cells incorporated in each jack shall be provided together with a pressure metering device.
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Other continuous records, including cutter torque, rate of progress, slurry pressure, slurry
flow, pitch, roll, and earth face pressure shall be provided. Copies of these records shall be
submitted daily to the Engineer.
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7 The thrusting force shall not exceed the maximum permissible force stated in the method
statement. Thrust pressure shall be monitored and controlled to ensure that the pipe joint
deflection does not exceed the maximum permitted angular deflection of 1 .
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9.8 LUBRICATION HOLES
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1 Lubrication holes shall be threaded to enable plugs to be screwed into the socket and to
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withstand external pressure. A non-return valve shall be fitted where opening a lubrication
hole would permit ground loss. Upon completion of grouting, the plugs shall be covered with
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material similar to that of the pipes. The pressure of the lubricant shall be maintained until it
is replaced by grout.
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9.9 RECORDS
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1 The Contractor shall maintain and submit to the Engineer after each day a log which records
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the following information:
(a) location of drive, between manholes

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(b) strata encountered

(c) position and orientation of the pipes
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(d) thrusting pressure used on both main and interjack rams during driving of each pipe
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(e) line and levels of pipeline constructed including details of angular deflection at joints
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(f) roll of pipejacking shield

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(g) average length of pipeline constructed per shift

(h) thrust from ground on face of machine
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(i) readings of oxygen, methane and hydrogen sulphide gas at the excavating face
(j) volume of excavated materials removed
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(k) volume of grout used, the points of injection and pressure at the points of injection
(l) Contractor’s operating personnel.
9.10 TESTING
9.10.1 General
1 Upon completion of the permanent construction of the pipeline, it shall be tested for
watertightness, alignment, condition and soundness, and all other designated requirements.
2 In the event of the Works failing a test, the Contractor shall take such remedial action as is
necessary, subject to the Engineer’s approval of the methods proposed. The Works shall
then be retested until such time as the Works pass the test.
9.10.2 Watertightness
1 Leakage tests shall be carried out in accordance with Clause 4.5.4 of this Section.
END OF PART
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QCS 2014 Section 08: Drainage Works Page 1

Part 01: General

1 Documents of the following agencies are referred to in this Section:

American Society for Testing and Materials, ASTM

British Standards Institution, BS

Swedish Standards Commission, SS

BS 6100 ......................Glossary of building and civil engineering terms

1.1.4 System Description

(a) be capable of providing the required level of service

Section, the Project Specification, and required by variations. Submittals shall be in

drawings shall be provided by the Contractor as required by Section 1 Part 21.

these drawings are in all respects a true record of the installation.

representative for approval before the contract completion date.

PIPE LINE AND APPURTENANCES PUMPING STATIONS

b) Discharge Chamber Record (2 b) Pumping Station Hoist Inventory Sheet

d) Valve Inventory d) Pumping Station Penstock Inventory Sheet

e) Valve Chamber Survey (3 pages) e) Pumping Station Data Sheet

h) TSE Tower Record h) Pumping Station Valve Inventory Sheet

l) House Connection Record l)

n) Gully Record n) Pumping Station Control Panel Inventory

p) Pumping Station Air Conditioner Sheet

above list be altered by PWA from time to time.

become the property of the Employer.

12 No valuation of sections of work will be considered in the absence of completed record

16 All Survey works shall be undertaken by Survey Company approved by Engineer.

1.1.7 Site in Private Lands

constructing the Works only.

1.1.8 Inspection and Handover Procedure

1.2 TESTING OF MATERIALS

1.2.1 Materials Generally

1.2.2 100 Day Acid Test

shall be taken in preparation of samples of non-homogenous materials to ensure that only

during the testing.

material with the protective coating to be tested.

(a) The test procedure adopted.

1.3.1 Site Information

1 Notwithstanding any relevant information included or referred to in the Project Specification

services information sheet has been approved by the Engineer.

3 Blank services information sheets will be provided by the Engineer.

1.3.2 Health and Safety

existing manhole or confined space.

10 Particular attention is drawn to the dangers of poisoning, asphyxiation or explosion while

(a) Sufficient numbers of covers of manholes or chambers upstream and downstream of

such gas monitors are not in use.

Safety Harness (not a safety belt) and ropes 1 No.

Gas monitor 1 No.

Mechanical air blower with compressor and generator 1 No.

15 Gas monitors shall incorporate the following features:

1.3.3 Setting Out of the Works

1 The following requirements are pursuant to or in addition to the requirements in Section 1.

(v) positions of additional temporary control points shall be determined by

3 On completion of work, all observations, computations, sketches and any other

1.3.4 Inspection of Works

(a) setting out

1.3.5 CCTV Survey

1.3.6 Compensation for Damage to Property

2.1 GENERAL ...................................................................................................... 2

2.2.12 Trimming and Levelling 11

2.2.13 Excavations Not to be Left Open 11

2.3 BACKFILL .................................................................................................... 13

2.3.1 Pipe Bedding 14

2.3.4 Backfilling Excavation 17

2.3.5 Backfilling Excavations with Cement-Bound Granular Material 19

2.3.7 Backfilling Next to Pipeline Structures 22