00 Ca e 10150 - 02 PDF

Client: Document No.
00-CA-E-10150
Contractor: PEDEC Consultant:
NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )
ENI Iran B.V PETROLEUM ENGINEERING & DEVELOPMENT COMPANY Snamprogetti S.p.A.
SAZEH ENGINEERS. ARCHITECTS.
DARQUAIN OIL FIELD CONSULTANTS
NICO Second Stage of Development
Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 1 of 103 Rev.: 2
GENERAL SPECIFICATION
FOR
CIVIL WORKS
2 Issued for Construction V.Moradi B.Hoseinzadeh N.Soia G.Lorio 15.08.06

1 Issued for FEED Di Genua R. Lenzi M. Bellinzona A. INTRIVICI Oct. 04
0 Issued for Design Di Genua R. Lenzi M. Bellinzona A. INTRIVICI 15.07.2004
ENI IRAN
Rev. Description JV - Prepared JV - Checked JV - Approved Date
Approved
Client Job No.: Client: Document No.:
00-CA-E-10150
ENI Iran B.V NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )

PETROLEUM ENGINEERING & DEVELOPMENT COMPANY Snamprogetti S.p.A.
NICO DARQUAIN OIL FIELD CONSULTANTS
Second Stage of Development
CONTENTS
A. SCOPE
B1. CONCRETE WORKS
1. GENERAL
1.2 References
1.3 Symbols and Abbreviations

2. MATERIALS
2.1 Cements
2.2 Admixtures
2.3 Mixing Water
2.4 Aggregate
2.5 Reinforcement
2.6 Anchor Bolts

3. PROPORTIONING AND CONCRETE CHARACTERISTICS
3.1 Grades of Concrete
3.2 Durability
3.3 Consistency and Workability
3.4 Mix Proportioning

4. CONCRETE CONSTRUCTION WORKS
4.1 Blinding Concrete
4.2 Formwork
4.3 Reinforcement
4.4 Joints and Embedded Items
4.5 Production of Concrete
4.6 Placing of Concrete

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4.7 Finished Surfaces
4.8 Concrete Curing, Protection and Patching
4.9 Tolerances
4.10 Special Constructions
4.11 Concreting in Hot Weather

5. IN SITU CHECKS AND TESTS
5.1 Pre-placement Checks
5.2 Placement Checks
5.3 Post-placement Checks
5.4 Field Tests
5.5 Tightness Test for Basins and Pits

6. DOCUMENTATION
6.1 Documentation for the Material Prequalification
6.2 Mix Design Documentation
6.3 Other Documentation

B2. EXCAVATION WORKS
1. GENERAL
1.2 Reference Documents
1.3 Definition of Excavation Types
1.4 Definitions of Excavation According to the Soil Nature

2. METHODS OF EXCAVATION
2.1 Requirements
2.2 Tolerances
3. WORK PROCEDURES
3.1 Employer's Requirements and Obligations
3.2 Contractor's Obligations

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3.3 Activities Subject to Approval
3.4 Use of Excavation Materials

B3. FILLING WORKS
1. GENERAL

2. CLASSIFICATION OF FILL
2.1 Fill according to the source of materials
2.2 Fill According to Destination

3. MATERIAL
3.1 General Requirements
3.2 Special Requirements for Material from Borrow Pits

4. FILLING WORKS
4.1 Setting Out
4.2 Preparation of Subgrade
4.3 Method of Construction
4.4 Tolerances
5. SURFACE FINISHING
5.1 Topsoiling
5.2 Placing of Gravel Layer

B4. ROAD WORKS
1. GENERAL
1.1 Scope and Field of Application
1.3 Definitions
2. MATERIALS
2.1 Sub-bases
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2.2 Base Courses
2.3 Pavements
2.4 Materials for Bituminous Mixtures
2.5 Precast Concrete Kerbs
2.6 Guardrails
2.7 Traffic Paints

3. ROAD WORKS
3.1 Setting-out
3.2 Sub-grades
3.3 Tolerances
3.4 Road Sub-bases
3.5 Roadbases
3.6 Paving
3.7 Concrete Kerbs
3.8 Guardrails
3.9 Traffic Paints (reflecting type)

B5. SEWERS AND DRAINS
1. GENERAL

2. MATERIALS
2.2 Special Requirements

3. WORK METHODS

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4. DRAIN ACCEPTANCE TEST
4.2 Particular Requirements

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A. SCOPE
This general specification gives the criteria for the execution of civil works to be
built on the DARQUAIN OIL FIELD DEVELOPMENT - IRAN.
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B1. CONCRETE WORKS
1. GENERAL
1.1.1 This specification defines the material characteristics, proportioning, concrete

characteristics, requirements for construction, in situ checks and tests, and the
documentation required, relevant to concrete works to be performed with
reference to U.S. codes and standards.
1.1.2 Concrete works shall conform to all requirements of ACI 301 “Specifications for
structural concrete for buildings”, except as modified by the supplemental
requirements of this specification, job specifications and any other contractual
documents.
1.1.3 This specification applies only to normal weight concrete (concrete for which
density is not a controlling attribute).
1.1.4 Definition of Terms
For the purposes of this specification, the following definitions shall apply:
1 The Company is ENI IRAN BV operator of the development operation on behalf

of the CLIENT (NIOC).
The “Engineer” and/or “Employer” is the Owner’s representative in charge of

quality control and his appointment will be notified in writing to the Contractor.
The “Contractor” is the civil works contractor who will be carrying out the works
covered by this specification.
The “Testing Agency” (TA) is the company/laboratory approved by the Owner

who will be carrying out the testing of construction materials.
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1.2 References
1.2.1 General
This specification shall be used in conjunction with the contract documents, with
any special requirements included in design specifications and drawings, and
with the following documents.
1.2.2 Project Specification
00-CA-E-10015 Specification for fabrication and erection of steel structures
00-CA-E-10010 Basic specification for building
00-CA-E-10001 Civil and Structural design criteria
IPS-C-CE-200 Construction std for concrete structure
IPS-C-CE-260 Construction std for fire proofing
1.2.3 Codes, Standards and Legislation
1.2.3.1 All materials, workmanship, testing and design (where applicable) shall be in
accordance with the latest edition of the codes and standards listed under 1.2.3.3,
except where otherwise specified in this paragraph or other contract documents.
1.2.3.2 Notwithstanding the requirements of the above point, the applicable technical legislation
in force must be complied with.
1.2.3.3 Codes and standards
ACI 117 Standard specifications for tolerances for concrete construction and
materials
ACI 211.1 Standard practice for selecting proportions for normal, heavyweight,
and mass concrete
ACI 301 Specifications for structural concrete for buildings
ACI 309R Guide for consolidation of concrete
ACI 347R Guide to formwork for concrete
ASTM A 185 Standard specification for steel welded wire fabric, plain, for concrete
reinforcement
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ASTM C 31 Standard practice for making and curing concrete test

specimens in the field
ASTM C 33 Standard specification for concrete aggregates
ASTM C 39 Standard test method for compressive strength of cylindrical

concrete specimens
ASTM C 94 Standard specification for ready-mixed concrete
ASTM C 143 Standard test method for slump of hydraulic cement concrete
ASTM C 150 Standard specification for Portland cement
ASTM C 172 Standard practice for sampling freshly mixed concrete
ASTM C 260 Standard specification for air-entraining admixtures for concrete
ASTM C 309 Standard specification for liquid membrane-forming compounds

for curing concrete
ASTM C 494 Standard specification for chemical admixtures for concrete
ACI 212 R “Admixtures for Concrete”
ACI 211.2 Recommended practice for selecting proportions for structural

lightweight concrete.
ACI 305 Hot Weather concrete.
ACI 308 Recommended practice curing concrete
ACI 316 Recommended practice for curing contraction of concrete

pavements and concrete bases.
ACI 515R Guide to the use of Waterproofing, Dampproofing, Protective

and Decorative Barrier Systems for Concrete
ASTM C 289 Standard Test Method for Potential Alkali-Silica Reactivity of

Aggregates
ASTM C 586 Standard test Method for potential Alkali Reactivity of

Carbonate Rocks as Concrete Aggregates. (Rock cylinder
Method)
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ASTM C 1218 Test Method for water-soluble Chloride in mortar and concrete
ASTM D 994 Specification for Preformed expansion joint filler for concrete
ASTM D 1751 Specification for preformed expansion joint filler for concrete
paving and structural construction
ASTM C 685 Specification for concrete made by volumetric batching and

continuous mixing
1.3 Symbols and Abbreviations
f ′c specified compressive strength of the concrete at 28 days (on

cylinders)
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2. MATERIALS
2.1 Cements
Cement shall conform to ASTM C 150.
Cement shall be of the Type II Portland cement with pozzolanic additives as

recommended in the Mandro Geotechnical summary report dated July 2002 (
prescriptions to be confirmed after finel soil investigation on the area). In
addition underground concrete shall be coated with bituminous protection to the
following specification:
Surfaces below ground level:
Surfaces below ground level shall be coated with a proprietary or bituminous

coating to give a total minimum thickness of 1mm. The bituminous coating shall
be an emulsion with a solids content of at least 55% bitumen and also
containing 10% of rubber latex compound.
With surfaces at grade to be painted as below this coating shall overlap the
ground level coating by 75mm. Care shall be taken to ensure a watertight seal
between the applied coating and the polyethylene sheet below the foundations.
Exposed external surfaces at ground level:
Exposed external concrete surfaces for a depth of 150mm below ground level
and 500mm above, or to underside of baseplates, whichever is the lowest, shall
be primed with a low viscosity primer and coated with two coats of a light grey
coloured epoxy paint with a minimum thickness of 125 microns per coat, or a
polymer modified cement system with a minimum thickness of 500 microns.
Where coating is to underside of baseplates it shall cover the grout.
Paint brands:
One of the following or equal approved brands shall be used:
a) Hempadur primer 0597 plus Hempadur Hi-Build 4523

b) Quickmast 173 primer plus Quickmast 40
c) Master Seal 550 by Master Builders
Application trials shall be carried out on chosen coating. Concrete surface

preparation and application shall be strictly in accordance with the
manufacturer’s recommendations.
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The cement used in the work shall correspond to the cement used when
selecting concrete proportions.
Cement test certificates shall be submitted to the Engineer. One brand of

cement shall be used throughout the work to maintain uniform colour and to
establish undivided responsibility.
Test Certificates shall be submitted to the Engineer whenever requested.
2.2 Admixtures
The admixtures shall comply with the requirements of the following appropriate
standards:
Air-entraining admixtures ASTM C 260

Water-reducing admixtures ASTM C 494
Retarding admixtures
Accelerating admixtures
Water-reducing and retarding admixtures
Water-reducing and accelerating admixtures
Water-reducing, high range admixtures
Water-reducing, high range and retarding admixtures
Air entraining admixtures shall comply with the requirements of ASTM C260
and shall be dosed automatically, in liquid form, at the batching plant.
Admixtures to be used in concrete shall be subject to prior approval of the

engineer.
Admixtures used in establishing the concrete proportions shall be then used in

the work.
Fly ash shall be according to ASTM C 618, slag shall be according to ASTM C
989 and silica fume shal be according to ASTM C 1240.
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2.3 Mixing Water
Water used for mixing and curing concrete, mortar and grouting, shall be
potable water with pH value between 6.5 and 8.5 and inorganic contamination
shall not exceed the values in the table below.
Form of Contamination Maximum Concentration

ppm %
Dissolved solids excluding those listed below: 2000 0.2
Sulphates, alkali carbonates or bicarbonates 1000 0.1
Chlorides 500 0.05
Suspended solids 2000 0.20
2.4 Aggregate
Fine and coarse aggregates to be used in concrete shall comply with the
requirements of ASTM C 33.
The grading of coarse aggregate shall be as per ASTM C 33 - Table “Grading
requirements for coarse aggregates”, size numbers 357, 57 and 7 as
appropriate.
The following considerations regarding the limits of chloride and sulphate
content in aggregates and concrete, and potential AAR in concrete are
described in this Specification and shall be strictly adhered to.
Max size of aggregate will be

the smallest between: - 1/5 of narrowest distance between forms
- 1/3 of the depth of slabs
- 3/4 of the min clear space between rebars
2.4.1 Chlorides and Sulphates in Concrete
Maximum total chloride content of hardened concrete at ages from 28 to 42

days expressed as percentage of water soluble chloride ion by weight of
cement:
Concrete containing embedded metal and Made with 0.15

type I & II Portland Cement
Test procedures shall conform to ASTM C 1218

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The total water soluble sulphate content of the concrete mix shall not exceed
4.0% SO3 by weight of the cement in the mix. The sulphate content, expressed
as SO3 shall be calculated from the sulphate derived from the cement, any other
cementitious material, the aggregate, any admixtures and any other source.
2.4.2 Alkali - Aggregate Reaction (AAR)
The Contractor shall ensure that the following procedure is complied with to
avoid the potential for AAR in the concrete mix.
1) The alkali content of the concrete shall be calculated from:
a
A=C×
100
where A = alkali content of the concrete (kg/m3)

C = maximum expected Portland cement content of the concrete
(kg/m3) or maximum expected composite cement content of
the concrete (kg/m3)
a = alkali content of the Portland cement (%) or the reactive alkali
content of the composite cement (%)
2) where the alkali content of the concrete mix is less than or equal to
3 kg/m3 the cement type as specified shall be used.
3) Where the alkali content of the concrete mix is greater than 3 kg/m3, the
Contractor shall conduct the standard test for Potential Reactivity of
Aggregates (Chemical Method) in accordance with the requirements of
ASTM C289 and ASTM C586.
4) Where the results of the standard test for Potential Reactivity of

Aggregates (Chemical Test) indicate an innocuous aggregate, the
Contractor shall use the cement type as specified.
5) Where the results of the standard test for Potential Reactivity of

Aggregates (Chemical Test) indicate a deleterious or potentially
deleterious aggregate, the Contractor shall take measures to lower the
alkali content of the mix. The Contractor shall obtain a written guarantee
from the cement manufacturer that the cement alkali content does not
exceed 0.6%. The cement alkali content is defined as the acid-soluble
equivalent sodium oxide content.
The Contractor shall submit cement manufacturer’s certificates, aggregate test

certificates and calculations to the Engineer as evidence of compliance with the
requirements of this clause.
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2.5 Reinforcement
Plain mild steel bars Grade I in accordance with DIN 1045.
Minimum Yield Stress 2200 kg/cm2
Deformed steel bars Grade II in accordance with DIN 1045.
Deformed steel bars Grade III in accordance with DIN 1045.
Reinforcing fabric mesh in accordance with BS 4483.
The reinforcement shall be free from obvious defects such as cracks, burrs,
burnings and from all substances (such as oil, grease or earth) that may impair
its performance.
2.6 Anchor Bolts
2.6.1 Anchor bolts shall be fabricated in accordance with design drawings.
2.6.2 Bolt assemblies shall be installed, as detailed on the construction drawings,

within the following tolerances:
Bolt projection : Plus 6mm - minus 0

Bolt location : Plus or minus 2mm from co-ordinated position
Bolt Verticality : 0.5% or 1 in 200
2.6.3 Bolts shall be secured in place by means of a suitable template, designed to

exclude concrete from bolt sleeves during pouring, to ensure that orientation
and alignment of the bolt is maintained during pouring and to ensure that the
nut bears fully on the anchor plate.
Exposed bolt threads shall be protected by suitable wrapping prior to placing

concrete.
When the formwork is being utilised to support metal inserts or fabricated items
such as holding down bolts which are to be cast-in, the arrangement shall be
such that inspection and dimensional checks can be undertaken by the
Engineer prior to placement of concrete.
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2.6.4 Following removal of the template, bolt sleeves shall be suitably protected to
ensure they do not fill with water and subsequently freeze prior to grouting.
2.6.5 Proprietary bolts, where specified, shall be installed strictly in accordance with
the manufacturer’s instructions. Expanding type bolts shall not be used.
2.6.6 In no case shall bolts be bent in situ by the application of heat.

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3. PROPORTIONING AND CONCRETE CHARACTERISTICS
3.1 Grades of Concrete
3.1.1 Unless otherwise specified on drawings or called for in the schedule of rates,
the following grades of concrete shall be used in the works:-
Cast in situ concrete f’ ’c = 280 kg/cm2
Precast concrete f’ ’c = 280 kg/cm2
Tanks of Reservoirs f’ ’c = 280 kg/cm2
Prestressed concrete f’ ’c = 300 kg/cm2
Foundation for vibrating equipment f’ ’c = 280 kg/cm2
Lean concrete/Blinding f’ ’c = 150 kg/cm2
Fire proofing concrete
(according to IPS-C-CE-260 sect 6) f’ ’c = 200 kg/cm2***

f’ ’c = 250 kg/cm2§§§
*** for poured or troweled concrete

§§§ for gun-applied concrete
Cylinders shall be manufactured in accordance with ASTM C31 and tested at

28 days in accordance with ASTM C39.
3.1.2 If cement is supplied in bags, the batches for the various quality of concrete
shall be proportioned in such a manner as to avoid the necessity of using part
bags in any batch.
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3.2 Durability
Requirements of ACI 301 chapter “Durability” shall apply together with any
project and contractual documents. The Contractor shall particularly note the
amount of sulphates and chlorides present in the soil.
As a minimum the following prescriptions shall be followed:
- Max water/ cement ratio : 0.50
- Min cement content : 330 kg / m3
(to be verified after execution of soil investigation in the area of the plant)
W/c ratio to be calculated considering the mass of cement+pozzolan (slag or fly

ash).
3.3 Consistency and Workability
Workability and consistency shall be such as to permit concrete to be worked

readily into forms and around reinforcement under conditions of placement to
be employed, without segregation or excessive bleeding.
The slump determined in accordance with ASTM C 143 shall range between the
following limits. The stated ranges are consistent with concrete made with
ordinary Portland cement. Changes due to use of super-plasticiser and cement
type II are expected. A highly qualified laboratory shall be consulted, for
obtaining allowable ranges of slump for the proposed concrete grades.
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The slump determined in accordance with ASTM C 143 shall range between the
limits indicated in table 4.4:
Table – 4.4
Recommended Range of Slump (cm), Using the

Type of Construction Indicated Consolidation Equipment
Tamping Rod Vibrators
Foundation Walls and Footings 7-11 4-8
Beams, Columns, and Walls 8-13 5-10
Floors 9-15 6-12
Pavements and Roads 7-10 4-7
Massive Concrete 6-9 3-6
Thin Section with Congested

Reinforcement 11-15 Not Recommended
3.4 Mix Proportioning
3.4.1 General
Proposed concrete proportions shall be subject to acceptance by the employer

based on demonstrated ability to produce concrete meeting all requirements of
this specification, of job specifications and any other contractual documents.
The selection of proportions for the concrete shall be preferably performed on

the basis of ACI 211.1 complying with strength and other job specification
requirements.
Workability and consistency shall be such as to permit concrete to be worked

readily into forms and around reinforcement under conditions of placement to
be employed, without segregation or excessive bleeding.
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3.4.2 Determination of required average strength on the basis of field

experience or trial mixtures
The value of required average strength shall be established, in accordance with

the procedures set out in ACI 301 paragraph “Proportioning on the basis of
previous field experience or trial mixtures”, on the basis of previous field
experience or laboratory trial batches when less than 15 tests are available.
The required average compressive strength to be complied with shall be

calculated on the basis of specified strength plus the amount determined in
accordance with the procedures established in above said standard.
Should trial mixtures be performed the test cylinders shall be tested for strength
in accordance with ASTM C 39 at 7 and 28 days.
Proportioning based on empirical data is not permitted unless the concrete is to

be used for non structural casting.
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4. CONCRETE CONSTRUCTION WORKS
4.1 Blinding Concrete
Regardless of the nature of the soil, all foundations shall be laid on a layer of
lean concrete having a minimum specified strength 150 kg/cm2 unless
otherwise specified in job specifications.
The minimum thickness of the blinding concrete, and its projection beyond the
foundation edges, shall be 50mm.
The blinding concrete shall be laid and compacted to the specified levels.
4.2 Formwork
4.2.1 General
In addition to the requirements of ACI 301 chapter “Formwork” the following

shall apply.
4.2.2 Fabrication and Erection of Formworks
The design and engineering of the formwork as well as its construction, shall be
the responsibility of the contractor; the formwork shall be designed for loads and
lateral pressure and for design consideration wind loads, allowable stresses,
and any other applicable requirements of the controlling local building code.
Timber or steel may be used for formwork fabrication.
Formwork must be able to withstand the dead load of the structure to be cast,
the loads of the workers and fixed and mobile equipment for concreting, as well
any other load or force.
Moreover, formwork shall be erected in such a way that plane distortions and
misalignments during concreting are prevented.
In particular, early stripping shall be possible, for horizontal structure formwork,

leaving the shoring props in place, in the required number and locations, until
the concrete supporting structure has reached the strength specified.
Timber formwork boards coming in contact with concrete shall be assembled in

such a way as to obtain surfaces without defects and to avoid loss of mortar
during concreting.
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When required and authorised by employer, plywood or steel panels may be

used if they are free of defects which could damage the concrete surfaces.
Boards and panels shall be uniformly arranged in such a way that the joints
between the panels/boards run horizontally or vertically.
The use of timber spacers/ties to be left in the concrete is forbidden; such ties
shall be made of steel bars with blocks of concrete at the end so that the steel
bars do not project from the finished concrete surface, or else they may be
made of suitable plastic elements.
Timber or plastic chamfer strips (25mm thick) shall be placed in the corners of
form to produce bevelled edges on permanently exposed surfaces.
To facilitate form removal, a release agent can be used by applying a thin layer
on the form surfaces.
4.2.3 Formwork for Exposed Concrete
For exposed concrete, smooth-surfaced forms shall be used, made of dressed

timber boards, with low resin content and free of knots which may damage the
finished concrete surfaces.
4.2.4 Openings
Temporary opening shall be provided at the base of column forms and wall
forms and at other points where necessary to facilitate cleaning and observation
immediately before concrete is placed.
During formwork erection, appropriate means shall be inserted at the right

locations, alignments and levels to provide anchoring and accommodation
pockets, holes and in general all passage openings (vertical or horizontal,
underground or above-ground), which may be required for subsequent
installation of all types of machinery and equipment, whether temporary or
permanent.
These means, which will consists of timber or metal boxes, PVC pipes of either
round or square section, polystyrene blocks suitably shaped, etc., must be
easily removable from the hardened concrete.
The pockets so formed shall be thoroughly cleaned before installation of

anchoring elements.
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4.2.5 Form Removal
Top form on sloping surfaces of concrete shall be removed as soon as the

concrete has attained sufficient stiffness to prevent sagging. Any needed repair
or treatment required on such sloping surfaces shall be performed at once and
be followed by the specified curing.
Formwork for columns, walls, sides of beams, and other parts not supporting
the weigh of the concrete may be removed as soon as the concrete has
hardened sufficiently to resist damage from removed operating.
Forms can be removed under ordinary conditions when the time recommended
by ACI 347R chapter “Removal of forms and supports” has elapsed.
In any case forms can be removed only when the concrete is strong enough to
carry the structure loads and when the forms are no longer necessary to
improve concrete curing. In addition the formwork shall remain in place for at
least the number of days (calculated from placement finishing date) required for
each type of structure by the legislation in force in the country where the works
are performed; a day is understood as an actual period of time of 24 hours.
In normal circumstances and where ordinary Portland cement is used, forms

may generally be removed after expiry of following periods.
Walls, columns and vertical faces 1-2 days.
Slabs (props left under)
Spanning up to 3.0 M 3 days.
Spanning over 6.0 M 7 days.
Beam soffits (props left under)

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Removal of props under slabs:
Removal of props under beams and arches:
Spanning up to 3 M 7 days.
Spanning up to 6 M 14 days.
Spanning over 6 M 21 days.
Cantilever Construction formwork shall remain till structures for

Counter acting or bearing down have been
erected and have attained sufficient strength
(minimum 14 days).
For other cements, the stripping time recommended for ordinary Portland
cement shall be suitably modified as per the instructions of the Engineer.
The number of props left under, their sizes and disposition shall be such as to
be able to safely carry the full dead load of the slab, beam or arch as the case
may be together with any live load likely to occur during further construction.
Formwork shall be removed with appropriate care to avoid shocks or impact

loads, so that the structure, or part thereof, is submitted to stress gradually, and
damage to the concrete surfaces is prevented.
In particular, before any form work or part thereof is removed, the concrete
placing record shall be checked to ascertain the prevailing weather conditions
when the concrete was placed and during the curing period, and any other
relevant particular conditions.
The concrete curing time and the consequent formwork removal dates shall be
referred to normal placing and curing conditions, otherwise it shall be extended
as required.
Upon completion of form removal, all elements and parts of formworks shall be
stripped from concrete surfaces, as well as ties, temporary fixings, etc.
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4.3 Reinforcement
4.3.1 General
In addition to the requirements of ACI 301 chapter “Reinforcement” the following

shall apply.
4.3.2 Fabrication of Reinforcing Steel
Reinforcing steel shall be cut and bent cold and conform to the shapes and
dimensions specified in the construction drawings.
No hooks shall be provided for deformed steel bars unless specified in the
construction drawings.
Min bend radius and dimensions of hooks shall be according to IPS-C-CE-220

sect. 13
Bars and fabric displaying defects, improper fabrication or non compliance with
the specifications shall be rejected.
Reinforcement which has been bent to facilitate transportation in short trucks
will be rejected by the Engineer.
Reinforcing bars shall be bent to conform to the shape and dimensions

specified on the construction drawings. All bending shall be done cold. Re-
bending or straightening shall not be permitted, except where shown on the
construction drawings, or with the prior written approval of the Engineer. Unless
permitted, reinforcement shall not be bent after being partially embedded in
hardened concrete.
Reinforcing bars when bent to schedules shall be securely bundled and labelled
with a metal tag, which shall be stamped with the bar mark and its identification
prefix as noted on the bar bending schedule.
Reinforcing bars shall be stored on suitable racks to avoid contamination. Wire
mesh reinforcement shall be stored on a level floor to prevent distortion.
Reinforcement mesh for fireproofing shall comply with IPS-C-CE-260 sect. 7.11
to 7.17.
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4.3.3 Placing of Reinforcing Steel
Reinforcing bars shall be free of any extraneous and deleterious matter that
could impair their adherence to concrete.
The number, size, form and position of all reinforcement shall be strictly in
accordance with the drawings, unless otherwise authorised by the Engineer in
writing.
Bars shall be tied using annealed iron wires at intersections, to form a rigid cage
that shall maintain its position without distortion or twisting while the concrete is
being placed.
Concrete cover shall be as specified in table 4.3 unless noted otherwise in the
TABLE 4.3 MINIMUM CONCRETE COVER TO ALL REINFORCEMENT

Unformed concrete cast against 75mm
ground
Formed concrete exposed to weather 50mm (bar size 20mm and more)
or in contact with ground 40mm (bar size 18mm and less)
Formed concrete columns and beams 40mm
not cast against ground or exposed to
weather
Formed concrete slabs and walls not 20mm
cast against ground or exposed to
weather
Chairs to support upper reinforcing bar mats will be shown where necessary on
the drawings, for slabs 800mm deep or greater, and where the unsupported
span exceeds 150 x D. In slabs less than 800mm, the contractor shall provide
chairs where necessary to give adequate support to reinforcing bars during
construction. D is the diameter of the largest unsupported bar.
Bars may be moved as necessary to avoid interference with other reinforcing

steel, conduits, or embedded items. If bars are moved enough to exceed the
above tolerances, the resulting arrangement of bars shall be subject to approval
by the Engineer. Extra bars may have to be added to maintain the design
requirements.
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To ensure that the required concrete cover is maintained until concrete

placement has been completed, suitable prefabricated concrete or plastic
spacers/bar supports shall be inserted between the bar outer edges of the
reinforcement cage and the internal surface of the formwork.
4.3.4 Provisions for Lightning Protection
When lightning protection is required for buildings, a direct conducting

downpath to the ground shall be provided (i.e. the route from the roof to the
connection point with the grounding system) by welding, or connecting, a
minimum of three reinforcing bars, in accordance with the construction
standards of lightning protection.
4.3.5 Cement and Aggregate
Test Certificates shall be submitted to the Engineer whenever requested.
Any sub standard material rejected by the Engineer shall be removed from the
site at the Contractor expense.
All delivery notes shall indicate the date supplied, description and quantity.
All materials accepted for use at site shall be properly stored to avoid
contamination or deterioration.
Cement shall be stored under cover at all times. Bagged cement shall be stored
in a well ventilated and weatherproofed building and to avoid undue
compaction, shall not be stacked more than 1.5 m high. Alternately, if bulk
cement is used, then it shall be stored in purpose made bins or silos which are
painted white.
After delivery of a cement consignment the Engineer shall, during working

hours, have access to the cement store and have the right to take samples for
further testing.
Cement shall be used in the sequence in which it is delivered.
Cement bags containing lumps that cannot be broken by a light touch of the
fingers shall not be used.
No cement shall be used after 3 months of storage at site.
Aggregate shall be stored in purpose made bins with sloping floors to ensure
adequate drainage.
Each type and grading of aggregate shall be kept in separate bins.

00-CA-E-10150

4.4 Joints and Embedded Items
4.4.1 General
In addition to the requirements of ACI 301 chapter “Joints and embedded items”
the following shall apply.
4.4.2 Construction Joints
Construction joints not indicated in the valid construction drawings shall be

carried out only after having received the employer’s approval; position and
construction shall be such as to minimise the impact on the strength of the
structure.
Construction joints in columns shall be positioned at the soffit of beams,

haunches or column capitals. Where required, kickers 100mm above slabs or
bases shall be shown on the drawings. All kickers shall be cast integrally with
the underlying base or slab.
Construction joints in beams and slabs shall generally be positioned at

approximately a third of the span from a support, unless noted otherwise on the
construction drawings. It is preferable to omit joints in single, simply supported
spans.
Construction joints shall be arranged to minimise the effect of shrinkage of the

concrete. Proposed location of the joints shall be approved by the Engineer.
Construction joints specified on the construction drawings shall not be omitted

or relocated without the prior written permission of the Engineer.
All construction joints other than horizontal joints shall be formed with proper
stop-boards, which shall be fixed vertically unless otherwise directed.
Prior to pouring new concrete, all exposed reinforcement shall be wire brushed
to ensure removal of all concrete residue from previous pouring operations.
Immediately prior to pouring new concrete, all joint faces shall be hacked clean
of all laitance and honeycombed concrete. Hacking shall terminate 12mm from
any exposed edge, and further be treated with cement water mix.
At vertical joints, the fresh concrete shall be placed directly against the hacked
concrete face which shall be thoroughly wetted immediately prior to pouring.
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Horizontal joints shall be prepared while the concrete is still “green”. The
surface skin shall be removed by means of an air-and –water jet or by wire
brushing, to expose the larger aggregate. This operation shall be carried out
one to three hours after compaction, depending upon weather conditions.
When it is impractical to carry out the above procedures the joints shall be
prepared by sand blasting or needle gun to remove the surface skin and
laitance. Hacking of hardened surfaces shall be avoided. Before commencing
with the fixing of reinforcement or shuttering for the new concrete, the surface of
the hardened concrete shall be inspected and approved by the Engineer.
4.4.3 Expansion and Control Joints
Expansion joint filter shall be of the type required and shall confirm to ASTM
D 994, ASTM D1751.
Expansion joints shall extend for the full depth of the concrete; control joints
shall be made by superficial cutting of the concrete.
The sealing operation of a joint shall be as follows:
- applying of masking tape on both sides of joint

- cleaning of joint seat
- inserting of close cellular backing cord, leaving the necessary space for
the mastic; underneath remaining space to be filled with expanded
polystyrene
- applying of tack primer coat
- applying of joint filler to seal perfectly the concrete joint
- removing of masking tape.
The joint filler shall be self-levelling hydrocarbon-resistant if it is to be used in

plant areas and/or in case of aggressive liquids, and shall have thixotropic
characteristics if the laying surface is inclined.
Application of the joint filler and joint size shall be in compliance with the
manufacturer's recommendation.
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4.4.4 Watertight Joints
When watertight joints are required premolded pvc pieces shall be buried in the
concrete, shaped in such a way as to absorb the expansion and the shrinkage
of the structures.
Full length premolded waterstop shall be used all along the joint up to the
maximum practicable length in order that the number of end joints will be held to
a minimum.
End joints shall be made in accordance with manufacturer’s recommendations.
4.5 Production of Concrete
Concrete produced by on-site volumetric batching and continuous mixing shall

be batched and mixed in accordance with and shall conform to all requirements
of ASTM C 685. Operation of batching equipment shall be such that the
concrete ingredients are consistently measured within the following tolerances:
Cements = 1 percent
Water = 1 percent
Aggregates = 2 percent
Admixtures = 3 percent
Concrete, either produced on site or ready-mixed as agreed with the employer,

shall comply with the requirements of ACI 301 chapter “Production of concrete”.
Ready mixed concrete shall be batched and mixed in accordance with ASTM
C 94.
The concrete mixing equipment shall be suitable for:
- the volume of the structures to be constructed

- the relevant concreting schedule, taking into account the need to ensure
continuous concreting for each structure.
The quantities and properties of the concrete components shall be constant and
consistent with those proved to be optimum during the preliminary tests for each
mix.
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4.5.1 Mixing
When concrete is mixed in a batching plant at least two separate plants shall be
provided.
The concrete shall be mixed in a batch mixer conforming to the requirements of

the “Concrete Mixer Standards” by the Mixer Manufacturers Bureau of the
Associated General Contractors of America, or any other batch mixer approved
by the Owner. The mixer shall bear the manufacturer’s rating plate indicating,
the rated capacity and the recommended rotational speed and shall be
operated in accordance with these recommendations. It shall be equipped with
a suitable charging hopper, water-storage tank, and a water-measuring device,
and shall be capable of thoroughly mixing the aggregates, cement, and water
into a uniform mass within the specified mixing time, and of discharging the mix
without segregation. The weighing equipment shall be recalibrated every 3
months.
Any liquid admixture shall be dispensed by means of an automatic dispenser or

similar metering device. Powdered admixtures shall be weighed as
recommended by the manufacturer.
The batch shall be so charged into the mixer that some water will enter in
advance of the cement and aggregates. Water shall continue to flow for a
period which may extend to the end of the first 25 per cent of the specified
mixing time.
Controls shall be provided to ensure that the batch cannot be discharged until
the required mixing time has elapsed. Controls shall be provided to ensure that
no additional water may be added during mixing. The entire batch shall be
discharged before the mixer is cleaned out and recharged.
Each batch of 1 m3 or less shall be mixed for not less than 2 minutes. The
mixing time shall be increased 20 seconds for each additional cubic metre or
fraction thereof.
The mixing period should be measured from the time when all the materials
including water are in the mixer. The mixer shall be clean, and the pick up and
throw over blades in the drum shall be replaced when they have lost 10 percent
of their original depth.
When mixing concrete, the cement and aggregates shall be measured by

weight with a tolerance of + 1% for cement and + 2% for aggregate. The water
shall be measured by means of a calibrated tank with an accuracy of + 1%.
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The water content of the aggregates shall be determined and shall be taken into
account when adding water to the mix.
The mixer drum shall be thoroughly washed out whenever a mix has been fully
discharged.
Retempering (addition of water to resolve slump lost during excessive mixing)

shall not be permitted.
4.6 Placing of Concrete
4.6.1 General
In addition to the requirements of ACI 301 chapter “Placing” the following shall
apply.
In the event of low and high temperatures specific procedures shall be issued
for the employer’s approval.
However no mixing or concreting shall be allowed at temperatures below 4°C

(included those expected 24 hr thereafter) unless specifically authorised by the
employer.
4.6.2 Transportation of Concrete
Concrete shall be transported to the placement areas by the fastest and most
suitable mechanical means so as to prevent segregation of the mix
components.
Unless the means of transport is equipped with a mixer, no longer than

15 minutes shall elapse from time the concrete is loaded to time it is placed.
4.6.3 Conveying of Concrete
Truck mixers, agitators and non agitators units and their manner of operation
shall conform to the applicable requirements of ASTM C94.
Pumping of pneumatic conveying equipment shall be of suitable kind with

adequate pumping capacity. Pneumatic placement shall be controlled so that
segregation is not apparent in the discharged concrete.
Concrete shall be handled to place of final deposit as rapidly as practicable by

methods which will prevent segregation or loss of ingredients and in a manner
which will assure that the required quality of the concrete is maintained (i.e.
conveyors, chutes, pumps, etc.).
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All plant and equipment used for transporting concrete shall be kept clean and
shall be thoroughly washed out whenever the mix has been fully discharged.
Runs or gangways for concrete transporters and main runs for foot traffic shall
not be supported from, or allowed to bear on, the fixed reinforcement.
In any case the maximum free discharging height shall not exceed 1.5 m.
4.6.4 Depositing of Concrete
Concrete shall be deposited as nearly as practicable in its final position to avoid

segregation due to rehandling or flowing. Concrete shall not be subjected to
any procedure, which will cause segregation.
After having carried out the preparation and checks, as per chapter 5.1, the
concrete can be placed.
Concrete shall be placed in subsequent layers, 300mm thick; all parts of the
section shall be filled and consolidated.
The placement shall be continuous and fill the whole section, both vertically and
horizontally, so that no setting occurs, during placement, at any of the contact
surfaces of the concrete sections. This requirement shall be strictly complied
with until each structural unit has been completed, or at least up to the pre-
determined construction joint locations.
The placed concrete shall be consolidated by vibrators.
Concrete shall be vibrated, within 15 minutes of placing, using compressed air,

electrical or mechanical vibrators (see ACI 309R table “Range of
characteristics, performance, and applications of internal vibrators”).
Vibrators shall be inserted and drawn out following the recommendations of ACI
309R paragraph “Procedure for internal vibration”, to prevent the formation of
voids inside the concrete. In general at a speed not exceeding 8 to 10 cm per
second.
Furthermore, contact between vibrators and any reinforcing bars shall be

avoided. The depth of each layer to be vibrated shall not exceed 400mm,
including 100mm of the previous layer. Vibration shall start and continue so
that the whole concrete volume is homogeneously consolidated, and shall
cease as soon as a thin film of mortar appears on the surface; further vibration
is not allowed since it may cause segregation of concrete constituents. Other
indicators for determining the adequacy of internal vibration are set out in ACI
309R paragraph “Judging the adequacy of internal vibration”.
00-CA-E-10150

In the presence of closely spaced reinforcing bars, blade vibrators shall be

used, the blade having a length not greater than 200mm.
Plate vibrators for formwork can be used on tall structural elements (e.g. walls)
and structural elements with small section (e.g. columns), and shall be applied
to the support member and not directly to the sheathing.
When concrete placement takes place in the presence of water, appropriate

equipment and methods shall be used to prevent concrete wash-out and to
ensure proper consolidation.
In placing concrete for walls and beams the work shall progress from both ends
to the middle for each layer deposited. Concrete in columns and walls shall be
allowed to stand for about one hour before placing concrete in beams or slabs.
In high walls, the concrete shall be placed to a height about 300mm from the
top and allowed to settle for about one hour before finishing the pour.
Prior to the commencement of the works the Contractor shall demonstrate the
efficiency of his proposed method of compaction, to the satisfaction of the
Engineer, on a trial section of the construction. Sufficient vibrators in
serviceable condition shall be on site so that spare equipment is always
available in the event of breakdowns.
Concrete for fireproofing shall be placed according to IPS-C-CE-260 sect.9.2

and 9.3
4.7 Finished Surfaces
4.7.1 General
The horizontal surfaces shall be level and wood-float finished; the surfaces in
contact with the form work shall be smooth, compact, with uniform planes, free
from colour patches, voids or burrs, after the form work has been removed.
Tie holes shall be plugged with cement mortar to match the adjoining concrete
in colour and texture.
Finished surfaces shall not have any defects that require repairs. Protruding
concrete formations that can be easily removed, any surface unevenness due
to placing or removal operations provided they are limited in quantity, and tie
holes shall be then repaired/plugged using mortar (made with the same type of
cement used in the concrete mix), in such a way as to obtain uniformity of
colour and surface.
Repair of surface defects shall be performed in accordance with ACI 301

chapter “Repair of surface defects”.
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4.7.2 Finishing of Formed Surfaces
Rough form finish shall be provided for all concrete surfaces not exposed to
view; smooth form finish shall be provided for concrete surfaces exposed to
view. Rough and smooth finishes are defined in ACI 301 paragraph “As-cast
finish”.
Special architectural finishes shall be provided when required by the valid for
4.8 Concrete Curing, Protection and Patching
The concrete shall be adequately protected and cured in accordance with the
requirements of ACI 301 chapter “Curing and protection” and the following.
Freshly deposited concrete shall be protected from premature drying and

excessively hot or cold temperatures, and shall be maintained without drying at
a relatively constant temperature for the period of time necessary for the
hydration of the cement and proper hardening of the concrete. All curing
procedures shall be in accordance with ACI 308 Standard Practice for Curing
Concrete.
Water shall be applied to formed surfaces while forms are still in place. Steeply
sloping and vertical formed surfaces shall be kept continuously moist prior to
and during form removal by applying water to top surfaces so that it will pass
down between the forms and the concrete.
Unformed surfaces shall be kept moist by wetting for at least 24 hours, and
curing shall be started as soon as the concrete has hardened sufficiently to
withstand surface damage. Spray nozzles shall be provided to keep covering
materials soaked.
The Contractor shall ensure that the curing water is not much cooler than the
concrete at all times during curing and the maximum temperature difference
between concrete and curing water shall not be more than 15 deg C. Water
mixed with ice shall not be used at any time during curing of concrete.
No person, vehicle, equipment or loading shall be allowed on any structure, or

part thereof, before the concrete is sufficiently hardened.
Protection for curing of the concrete after the initial set shall be by a method
such that adequate water is available for full hydration of the cement. This may
be attained by keeping the surfaces of the concrete damp by covering with a
layer of sacking, or a similar absorbent material, such as sand, which must be
00-CA-E-10150

kept soaked with water applied as fine spray. Alternatively, after thoroughly
wetting the surfaces they shall be covered with an approved waterproof paper
or plastic membrane kept in contact with the concrete, or immediately after
placing of the concrete or removal of the forms applying to the concrete
surfaces an approved liquid curing membrane, containing a dye, strictly in
accordance with the manufacturer’s instruction. Liquid curing membranes shall
not be applied to surfaces which will later receive grout.
Curing products, in accordance with ASTM C 309, can be applied to provide a

sprayed-on membrane cure for the purpose of improving the concrete setting
and reducing moisture loss during curing time.
Curing compounds shall be applied in accordance with the recommendations of

the manufacturer and shall not be used on any surfaces against which
additional concrete or other cementitious finishing materials are to be bonded.
Some of these compounds contain a dye and care should be taken to ensure
that it does not spoil the finished surface.
For massive castings, the Engineer will verify that heat of hydration during
curing of concrete do not cause a temperature differential between the interior
of the concrete and any outside face greater than 20° Centigrade. Prior to pour
approval the Contractor shall submit to the Engineer details of temperature
differential control procedure. When required by the Engineer, for castings with
thickness greater than 1 m, the Contractor shall prove the differential using
embedded thermocouples for 10 days after the concrete pour and also the
anticipated differential by calculation.
Curing shall be continued for a period of min 14 days, unless it is proved by

compression samples crushing that the required resistance is reached before
14 days; in no case the curing time shall be less than 7 days.
Steel forms heated by the sun and all wood forms in contact with the concrete
during the curing period shall be kept wet. If forms are to be removed during
the curing period, one of the curing methods stated above shall be employed
immediately, and for the remainder of the curing period.
Immediately after the forms have been removed, all exposed concrete surfaces
shall be inspected for defects, and all fins, bulges, projections, honeycombing,
and other defects repaired before the concrete is fully matured. Defective
areas, such as honeycombed concrete, shall be cut back to solid concrete for
repair. If before or during this operation any reinforcing bar is exposed the
cutting out shall continue right round the bar to form a key. When reinforcing
bars are so exposed, care should be taken to ensure that the bars or any other
inserts are not damaged by the tools used for cutting out the concrete.
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Patching of defective concrete shall be carried out with a suitable proprietary

epoxy resin mortar. All surface preparation, mixing, placing and curing shall be
carried out strictly in accordance with the manufacturer’s instructions.
Concrete for fireproofing shall be cured and finished according to IPS-C-CE-260

sect.9.4
4.9 Tolerances
Tolerances for concrete construction are established in ACI 117.
In particular the above standard deals with the following tolerances:
- reinforcing steel fabrication

- reinforcement placement
- vertical alignment, level alignment, cross-sectional dimensions, relative
alignment, etc. for various type of finished concrete works.
4.10 Special Constructions
4.10.1 Red Coloured Concrete
A red colouring of the mix may be required for electrical or instrument cable
duct banks, covering slabs for trenches or electrical cables, and pavements
over cable routes.
This colouring shall be obtained during mixing by the addition of pigment (e.g.
approximately 5 kg of iron oxide powder per cubic metre of concrete mixture).
4.10.2 Pits
For good performance of concrete pits the following requirements shall be

complied with during construction work.
Perfect wall sealing has to be ensured at piping inlets and outlets.
Even when a rendering is specified, the concrete characteristics, the surface

finishes and the sealing around pipe inlets and outlets shall ensure the pit
watertightness.
In the case of prefabricated cover slabs, the pit surfaces which supports the
slab shall be levelled with mortar of the type defined in spc. 00-CA-E-10010.
00-CA-E-10150

4.10.3 Slabs
Special requirements are set out in ACI 301 chapter “Slabs”.
4.10.4 Architectural Concrete
Special requirements are set out in ACI 301 chapter “Architectural concrete”.
4.10.5 Massive Concrete
Special requirements are set out in ACI 301 chapter “Massive concrete”.
4.10.6 Temperature Changes
Changes in temperature of the air immediately adjacent to the concrete during

and immediately following the curing period shall be kept as uniform as possible
and shall not exceed 6°C in any 24 hr period.
During Hot weather provision for wind breaks, shading, fog spraying, sprinkling,
ponding or wet covering with a light coloured material shall be made in advance
of placement, and such protective measures shall be taken as quickly as
concrete hardening operation will allow”.
4.11 Concreting in Hot Weather
The concrete shall be treated according to the prescriptions of ACI 305 “Hot
Weather Concreting” .
The temperature of concrete at placement shall not exceed 30° C , and , for
structures over 915 mm thickness, 26° C.
4.11.1 Cement and Aggregates
Further to Clause 4.3.5 of this specification, it shall be observed that cement

must not be subjected to temperatures greater than 77 deg C and that coarse
aggregates shall be heavily sprayed with water immediately before mixing.
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4.11.2 Water
In order to keep the concrete temperature as low as possible effort shall be

made to use water from a cool source and to keep it cool by protecting pipes
and tanks. Pipelines for conveying mixing water shall be buried, insulated,
shaded, or painted white. Water storage tanks shall be treated in a similar
manner.
Water may be cooled by adding ice provided it is completely melted by the time
the water is entered into the mixer.
4.11.3 Placing
The Contractor shall have ample personnel available to handle and place
concrete immediately on delivery. The temperature of concrete at placement
shall be according to section 4.11.
4.11.4 General
A combination of hot, dry weather and high winds or high temperatures resulting
in immediate vicinity of the formwork shall be sprinkled with cool water. All
subgrade foundation etc., which are to receive concrete shall be wetted down or
flooded with water immediately before concreting, preferably during the night for
early morning concreting, as directed by the Engineer.
00-CA-E-10150

5. IN SITU CHECKS AND TESTS
5.1 Pre-placement Checks
Before concrete is placed for a structural element or part thereof, the following
checks shall be carried out:
1) Lines and grades (location, elevation, dimensions, shape, preparation of

surface, bearing).
2) Forms (specified type, location, dimensions, tolerances, alignment,

stability, surface preparation, tightness, chamfer strips, inspection
openings, cleanliness, temperature, accessories such as ties, clamps,
etc.).
3) Reinforcing steel fully complies with the design requirements particularly

as regard the grade, number, position, spacing, diameter and length of the
bars, bends, splicing, staggerings, concrete cover; furthermore the cage
fixing shall be checked to ensure that the bars are held in position during
concrete placement (wiring, chairs, and spacers) and for cleanness (no
loose rust, oil , paint, dried mortar, etc.).
4) Check all boxes for making any required pockets (quantity, size, location
and elevations)
5) Check that all bolts, holding down bolts, sleeves, plates, pipes and the like
have been provided correctly (quantity, dimensions, type, diameter, levels,
alignments, position as required in the valid for construction).
5.2 Placement Checks
For the placement of concrete of a structural element or part thereof, the

following checks shall be carried out:
1) Conditions (co-ordination of concrete delivery, protection against sun,

rain, hot- or cold-weather conditions, lighting and power)
2) Field tests of concrete (use of specified mix, temperature, discharge of

ready-mixed concrete truckload before 300 revolutions or 90 minutes)
3) Conveyance of concrete (non-reactive materials, prevention of

segregation and loss of materials, prevention of contamination, condition
of conveying equipment, use of drop-chute or funnel hoses to contain
freefall)
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4) Placement and consolidation of concrete (preparation of contact surfaces,

ability of conveying method to place concrete in all areas of the
placement, prevention of segregation i.e. no chuting or dropping against
forms or reinforcement, depth of layer, vibration, even layering around
openings and embedments, removal of bleed water, removal of temporary
ties and spacers).
5.3 Post-placement Checks
After placement of concrete of a structural element or part thereof, it shall be

checked that finishing, curing, formwork and shore removal are correctly carried
out (specified finish, protection of surfaces from cracking due to rapid drying i.e.
avoiding direct heat, proper curing temperature, form removal, curing
compound, finish of formed surfaces, patching and repairs where necessary).
5.4 Field Tests
5.4.1 General
The procedure set out in ACI 301 chapter “Testing” is replaced by the
requirements of the following paragraphs.
5.4.2 Concrete strength tests
Sampling shall be in accordance with ASTM C 172. Each sample shall be

obtained from a different batch of concrete on a random basis, avoiding any
selection of the test batch other than by a number selected at random before of
concrete placement.
Mould and cure of three specimens from each sample shall be in accordance
with ASTM C 31.
Specimens shall be tested in accordance with ASTM C 39. Two specimens

shall be tested at 28 days for acceptance and one shall be tested at 7 days for
information. The acceptance test results shall be the average of the strengths
of the two specimens tested at 28 days. If one specimen shows evidence of
improper sampling, moulding or testing, it shall be discarded and the strength of
the remaining cylinder shall be considered the test result. Should both
specimens in a test show any of the above defects, the entire test shall be
discarded.
Samples for strength tests of each class of concrete placed each day shall be
taken not less than once a day, nor less than once for 100 m³ of concrete, nor
less than once for each 500 m² of surface area for slabs or walls. When the
total quantity of concrete with a given mixture design is less than 50 m³, the
00-CA-E-10150

strength tests may be waived by the employer if, in his judgement, adequate
evidence of satisfactory strength is provided, such as strength test results for
the same kind of concrete supplied on the same day and under comparable
conditions to other work or other projects.
On a given project, if total volume of concrete is such that frequency of testing

would provide less than five strength tests for a given class of concrete, tests
shall be made from at least five randomly selected batches or from each batch if
fewer than five batches are used.
The strength level of the concrete will be considered satisfactory so long as the
averages of all sets of three consecutive strength result does not fall below the
specified strength f ′c, and no individual strength test result falls below the
specified strength f ′c by more than 35 kg/cm2.
5.4.3 Concrete Slump Tests
Slump of the concrete sample shall be determined for each strength test and
whenever consistency appears to vary using ASTM C 143.
5.4.4 Additional Tests
Additional tests may be required by job specification or other contractual

documents.
5.5 Tightness Test for Basins and Pits
5.5.1 General
Watertightness checks shall be carried out on all basins containing liquids and
on sewer pits for which it is expressly required.
The tests shall be carried out upon completion of the works, including piping
and any other insert, and before backfilling.
All walls, construction joints and piping intersection shall be carefully inspected
to ascertain that there are no leaks or infiltrations.
During the testing period no water shall be added to restore the original level.
The test is considered successful in the absence of leaks.

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In the event of unsuccessful results, all the defects shall be eliminated even
though this may require demolishing, remaking, waterproofing, coating and/or
special material treatment.
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Defective works shall be re-tested after all defects have been repaired or
removed, until completely satisfactory results are attained.
5.5.2 Requirements for Basins
The test shall be carried out by filling the basins with water up to the design
level.
All piping and nozzles shall be carefully plugged to prevent any leak.
Before checking the watertightness, at least 24 hours shall elapse after filling, to
allow for possible absorption of the walls, and after having restored the original
test water level, if necessary.
5.5.3 Requirements for Sewer Pits
Pipes shall be plugged by pneumatic closing device, installed into the pipes at
the pit wall, or by any other method having equivalent efficiency.
Before checking the tightness, at least 12 hours shall elapse after filling, to allow
for possible absorption of the walls, and after having restored the original test
water level, if necessary.
Each pit shall be tested for tightness by maintaining the water level constant for
at least 30 minutes.
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6. DOCUMENTATION
6.1 Documentation for the Material Prequalification
The following documentation shall be produced prior to the commencement of

concrete work, in accordance with the referenced codes and standards for the
prequalification of the materials:
- material certificates for coarse and fine aggregate (grading and fineness
modulus, amount of material finer than No. 200 sieve, soundness, specific
gravity and absorption, water soluble chlorides, reactivity of aggregate,
bulk unit weight, petrographic examination)
- material certificates for fine aggregate (organic impurities, effect of organic
impurities on strength)
- material certificates for coarse aggregate (abrasion, flat or elongated
particles, friable particles)
- mill certificates for cement (physical properties, chemical properties)
- certificates for suitability of water (potability or mortar strength versus
control, time of set of mortar versus control, total solids content, total
chlorides)
- technical sheets for admixtures containing, but not limited to, the following
indications:
• field of application
• instruction for use and storage
• physical and chemical composition
• side effects (positive and negative)
• proportioning of admixture in % (by mass) of cement
• chloride content
• instructions for mixing with concrete.
- material certificates for reinforcing bars (mill test reports with tensile and
chemical properties)
- manufacturer’s certification that the welded wire fabric has been
manufactured in accordance with and meets the requirements of
applicable standards
- type of release agent for formwork
- types of spacers for concrete cover and formwork ties
- hydrocarbon resistant mastic technical sheets
- joint material technical sheets.
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6.2 Mix Design Documentation
The following documentation shall be produced prior to the commencement of

concrete work, in accordance with the referenced codes and standards for the
mix design approval:
- schedule of preliminary trial tests for the determination of the mixes

- results of concrete preliminary trial tests which documents that the
proposed concrete proportions will produce an average strength equal to
or greater than the required average strength (field strength record,
several strength records, or trial mixtures)
- documentation of proposed batching plant or source of ready-mix
concrete supply
- procedures for operations necessary to reach a good concrete curing.
6.3 Other Documentation
During execution of the works the following documentation shall be produced:
- concreting schedule for large placement or long placement (more than 1

day) indicating the sequence of interruptions and resumptions;
- concreting records (showing: commencement/end of placements, type of
concrete, weather conditions during placement and curing, any particular
remarks, etc.) for each structure or part thereof.
- results of tests performed on concrete (compressive strength and slump).
In addition all documentation required by the field quality control plan issued by
the employer shall be produced.
The above documentation shall be in accordance with the following tables.

00-CA-E-10150

abstract from ACI 301-99

ed. 2000.
00-CA-E-10150

B2. EXCAVATION WORKS
1. GENERAL
Excavation shall be carried out mechanically by Contractor’s selected methods

which shall be submitted for review to owner. Special care may be required by
Contractor to ensure no damage occurs to existing buried pipes or cables, if
any. Adequate protection shall be provided.
1.1.1 This specification defines the types, methods and procedures of excavation.
Excavation by means of explosives is not covered by this paragraph.
1.1.2 This specification applies to topsoil removal, general excavation, limited section
excavation, made in soil, soft or hard rock, whether in the presence of water or
not.
ASTM D-653 Terminology relating to soil, rock and contained fluids.
ASTM D-1556 Test method for density and unit weight of soil in place by
the sand cone method.
ASTM D-1557 Test method for laboratory compaction characteristics of

soil using modified effort
ASTM D-2216 Test method for laboratory determination of water content

of soil and rock.
1.2.1 This paragraph shall be used in conjunction with the Contract documentation,
any special requirements, and paragraph B3 of this specification.
1.2.2 Codes, standard and legislation
AI (Asphalt Institute) AI MS-1 Thickness design, AI MS-4 Asphalt, Handbook.

ASTM D 1883 Test method for CBR (California bearing ratio) of laboratory
compacted soils.
1. Item Road Types and Width of Roads:

Roads widths and slopes shall be as per NPCS Standards.
Insides Battery limits the roads shall have a width of 6 metres without
shoulder. The roads are integrated into paving and road edge is marked
up by paint.
00-CA-E-10150

2. Transverse Slope
All roads tracks shall be transversely sloped, each side, the high point
being on the centre line of the road. Transverse slopes shall be 2% to
3%.
3. Longitudinal Slopes
Longitudinal slopes shall be 5% maximum for roads and tracks. However
the slope of road with light traffic and which is relatively short in length, as
access ways to a tank bund, longitudinal slope may be increased to 12%.
1.3 Definition of Excavation Types
1.3.1 Topsoil Removal
Topsoil removal means the excavation made along the ground profile to an
average depth of 0.20 m below ground level, in soils of any nature and
consistency excluding rock, to remove the superficial soil layer.
Topsoil removal also includes clearing of bush, grass, shrubs, and other
unsuitable material (for example debris); this material shall be removed using
the same mechanical equipment as for topsoil removal (for example bulldozer,
payloader, etc.).
1.3.2 General Excavation
General excavation means excavation made at any depth, with a horizontal

surface area greater than 150 m² and a minimum width of 3.50 m.
As an example, general excavation includes, but is not limited to, excavation for
grading and levelling of plant or construction areas, for cutting of embankments,
for construction of yards, roads, channels, buildings, pipe ways, foundations of
storage tanks, prilling and cooling towers, etc.
1.3.3 Limited Section Excavation
Bottom of trench shall be to a depth 0.2 m below the intended inverts level. The
width of trenches shall be + plus 0.2 m on each side if the exterior pipe diameter
is 400mm or less. If the diameter exceeds 400mm, the trench width shall have
a minimum of the pipe exterior diameter plus 0.8 m. But always the width of the
trench shall be as necessary for sheeting bracing and the proper performance
of the work:
00-CA-E-10150

a) Excavation for foundation works
This means limited section excavation made for footings, continuous

foundations, foundations for machinery, equipment and steel structures,
pits, walls, concrete trenches, etc.
b) Trench excavation
Trench excavation means limited section excavation for laying of sewers,

aqueducts, pipes and ducts in general, electric and instrument cables, etc.
Trench excavation also covers excavation for making openings in tank
earth bunds for the passage of pipes, cables and/or equipment, as well as
excavation for construction of ditches.
1.4 Definitions of Excavation According to the Soil Nature
1.4.1 Earth Excavation
Earth excavation means any excavation in soil of any nature and consistency,
which can be carried out without the use of a ripper, even in the presence of
stones provided the volume of individual stones does not exceed 0.5 m3.
1.4.2 Soft Rock Excavation
Soft rock excavation means any excavation in soft rock with uniaxial
compressive strength less than 25 MPa; these rocks can normally be broken by
suitable mechanical equipment and/or by ripper single cut.
1.4.3 Hard Rock Excavation
Hard rock excavation means any excavation in compact rock with uniaxial
compressive strength 25 MPa or greater; these rocks can normally be broken
only by mechanic methods and/or pneumatic jack hammer.
Removal of individual stones with volume not less than 0.50 m3 during earth or
soft rock excavation shall be regarded as excavation in hard rock.
1.4.4 Excavation in Water
Excavation in water means any part of excavation made below the level of the
water table and in the constant presence of groundwater such as to require the
installation and continuous use of drainage systems and/or equipment.
00-CA-E-10150

2. METHODS OF EXCAVATION
2.1 Requirements
2.1.1 The requirements in this specification shall apply whichever the geological soil
nature may be and in the presence or not of water.
2.1.2 All excavations shall comply with the sizes and elevations indicated in the
Drawings and/or required by the Employer.
2.1.3 With reference to the bench marks established by the Employer, the Contractor
shall set out the works in accordance with the elevations and alignments
indicated on construction drawings.
2.1.4 The bottoms of foundation excavations shall be made perfectly horizontal

and/or levelled to the specified elevation.
The compaction of excavation bottoms and of backfilling relevant to limited

section excavation or general excavation shall be in accordance with paragraph
B3 of this Specification.
2.1.5 To avoid collapse, the Contractor shall carry out any temporary works required
for supporting the sides of limited section excavations using shoring props,
supports and reinforcement of any kind and size, including steel sheet piles or
equivalent.
2.1.6 The use of explosives is forbidden.
2.1.7 Drainage of water from excavations, if required, must be carried out using
suitable equipment such as, for example, motor driven suction pumps,
submersible pumps, or well-point systems.
The drainage operations shall continue until the Works are completed, unless
otherwise agreed upon (see para. 3.3.3.).
2.1.8 Dumped materials resulting from excavations shall not be prejudicial to the
works, to the free drainage of surface water, or to existing structures.
2.1.9 Roots, shrubs, debris, plants, etc. from topsoil removal must always be
transported to dump areas.
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2.2 Tolerances
2.2.1 Tolerances on finished excavation, for dimensions, elevations and positioning

specified on design drawings, shall be as follows:
TOLERANCES
excavation bottom elevation +20/-50mm
slope and/or deviation of excavation
bottom surface referred to the level
required and/or determined by the ± 30mm
excavation bottom level tolerance
slope position (referred to
excavation centre line) +150/-10mm
excavation centre line + 40/-40mm
(for limited section excavation)
2.2.2 The specified slopes shall be complied with, notwithstanding the application of
the tolerances mentioned above.
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3. WORK PROCEDURES
3.1 Employer's Requirements and Obligations
3.1.1 Levels and co-ordinates shall be referred to the bench marks indicated by the
Employer.
3.1.2 The Contractor may require part of the limited section excavation to be carried
out during plant erection, by means of any kind of excavators, provided these
machines are of a size suitable for the locations and sections of excavation
within the plant areas.
3.2 Contractor's Obligations
3.2.1 The Contractor shall make his considerations, based on the information
concerning the sub-soil, for the best development of slopes, slope stability, and
selection of the most suitable plant and equipment that are necessary for the
excavation.
3.2.2 The Contractor shall not commence excavation before agreeing with the
Employer on the elevations of the ground before excavation.
3.2.3 No construction shall be started before the Employer has checked and
approved the excavation levels and formation.
3.2.4 If the excavation bottom is of unsuitable, the Contractor shall inform the
Employer and wait for instructions before carrying out further works.
3.3 Activities Subject to Approval
3.3.1 The Contractor may for his own reasons extend the excavation beyond the
required design dimensions only with the prior written approval of the Employer.
In such a case, the additional excavation performed shall not be included in the
bill of quantities for payment; the Contractor shall provide at his expense the
backfilling of the greater volume of excavation and perform the relevant
compaction, using suitable material in accordance with paragraph B3 of this
Specification.
3.3.2 The choice of the system/equipment to be used for the removal of groundwater
shall be approved by the Employer.
00-CA-E-10150

3.3.3 If access and/or operation with mechanical equipment is impossible from any
location, or if excavation is close to existing underground networks (pipes,
cables) or foundations, excavation may be performed by hand or by jack
hammer only after verification and written approval by the Employer.
3.4 Use of Excavation Materials
3.4.1 The materials resulting from excavation of any kind shall remain the property of
the Employer.
3.4.2 The material from excavation, if considered suitable, shall normally be spread
near the excavation, after the Contractor has verified that all the safety
requirements concerning minimum distances from the excavation edge are
strictly complied with.
3.4.3 If the material from excavation is not used immediately for backfilling, it shall be
stock piled in an area approved by the Employer inside the plant area and/or
construction site, for later use.
3.4.4 The materials which cannot be re-used or are considered unsuitable for other
works shall be dumped in an area agreed with the Employer either inside or
outside the plant area and/or construction site.
3.4.5 If the Contractor has to find the dumping areas outside the plant area and/or
construction site boundaries, the Contractor shall submit to the Employer a list
of these areas and their relevant distances. The Employer can either choose
one of the solutions proposed by the Contractor or other solutions considered
more appropriate.
00-CA-E-10150

B3. FILLING WORKS
1. GENERAL
1.1.1 This paragraph covers the materials, requirements and methods of construction
for fill, with reference to U.S. codes and standards.
Fills are classified according to the source and destination of the materials.
1.1.2 This paragraph is applicable to filling, embankments, backfilling and surface
finishing by means of gravel or topsoil.
1.2.1 This paragraph shall be used in conjunction with the contract documentation,
any special requirements and the paragraphs B3 and B4 of this specification.
1.2.2 Codes and Standards
The latest edition of the following codes and standards shall be applicable:
ASTM C 131 Standard Test Method for Resistance to Degradation of Small-
Size Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine
ASTM C 136 Standard Method for Sieve Analysis of Fine and Coarse
Aggregates
ASTM C 535 Standard Test Method for Resistance to Degradation of Large-
Size Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine
ASTM D 422 Standard Test Method for Particle-Size Analysis of Soils
ASTM D 1241 Standard Specification for Materials for Soil-Aggregate Sub-
base, Base, and Surface Courses
ASTM D 1556 Standard Test Method for Density and Unit Weight of Soil in
Place by the Sand-Cone Method
ASTM D 1557 Test Method for Laboratory Compaction Characteristics of Soil
Using Modified Effort (56,000 ft-lbf/ft³(2,700 kN-m/m³))
ASTM D 3282 Standard Classification of Soils and Soil-Aggregate Mixtures
for Highway Construction Purposes
00-CA-E-10150

ASTM D 4318 Standard Test Method for Liquid Limit, Plastic Limit, and
Plasticity Index of Soils
00-CA-E-10150

2. CLASSIFICATION OF FILL
2.1 Fill according to the source of materials
2.1.1 Material from Excavation
Material coming from stock piles located in the site area and/or coming directly
from excavation operations.
2.1.2 Material from Borrow Pits
Material supplied from borrow pits located inside and/or outside the plant and/or
construction site area.
2.2 Fill According to Destination
2.2.1 Structural fill for general filling of areas and for embankments
This fill is to be used for general filling to design elevations in areas to be

subsequently used as support of the following:
− reinforced concrete foundations (footing, raft, etc.)

− buildings
− reinforced concrete basins and trenches
− storage tanks
− sub-base and base courses for roads, parking areas, operating areas for
trucks, cranes, etc.
− railway
− local replacing of unsuitable material
− paved areas
− pipeway.
2.2.2 Structural fill for general filling of areas with existing works
This structural fill and/or backfill is to fill to design elevations the areas to be
subsequently used as support of the works listed at paragraph 2.2.1 above, and
is carried out in the presence of existing foundations and/or above-mentioned
works.
Filling and backfilling are eventually carried out manually when the limited
space does not allow the use of mechanical equipment.
00-CA-E-10150

2.2.3 Structural fill for tank foundations
2.2.3.1 Tank pad
This structural fill can be used on the whole bearing surface of the tank load, or
inside a reinforced-concrete or crushed-stone ring; depending on requirements,
the filling material may be:
a) soil-aggregate mixture
b) granular material
c) sand.
2.2.3.2 Ring
This structural fill made of crushed stone is used to form the trapezoidal section
ring, which shall bear the load transmitted by the tank shell.
2.2.4 Non-structural Filling for Bund Walls
This fill is to be used for non-structural embankments, for example retaining

walls for storage tanks, basins, evaporation ponds, etc.
2.2.5 Non-structural Filling for Areas
This is to fill to design elevations the areas not to be subsequently used as

support of the works listed at paragraph 2.2.1 above, gravelled areas, and open
areas where filling is required only to reach design elevations.
2.2.6 Non-structural Backfilling of Trench Excavation
This backfilling is to be carried out after laying buried cables and/or pipes in
areas not to be used as support of the works listed at paragraph 2.2.1 above.
2.2.7 Replacing Unsuitable Material
This fill is to replace the existing soil (if unsuitable) with a better material.
2.2.8 Foundations for concrete pavement
This fill, with thickness between 150 and 300mm, is to adequately support
concrete pavement; it is to be properly shaped according to the pavement slope
to maintain a uniform thickness of the pavement.
00-CA-E-10150

3. MATERIAL
3.1.1 Material from excavation, which the employer considers suitable for the various
kinds of filling to be done, shall be used up completely.
In any case the contractor shall request the employer's written authorisation
before using this material.
3.1.2 Should suitable material from excavation be insufficient for the required filling,
the amounts of materials needed shall be taken from borrow pits, provided that
they meet the requirements for the various types of filling.
3.1.3 The contractor shall carry out all preliminary checks and laboratory tests on
material samples from borrow pits in order to verify their suitability for the
various kinds of filling.
The number and type of tests shall be agreed upon with the employer.
The results of the tests shall be submitted to the employer for approval of the
materials before the commencement of the works.
3.1.4 All or part of the material from borrow pits or excavation may require preliminary
treatment (sieving, crushing, mixing or other treatment) before being suitable for
use as fill.
The necessity to apply the above treatments, and the treatment type and
methods, shall be established after laboratory tests and analysis performed by
the contractor.
For material from excavation, before approving any treatments the employer
reserves the right to evaluate their cost-effectiveness as compared with material
from borrow pits.
00-CA-E-10150

3.2 Special Requirements for Material from Borrow Pits
3.2.1 Material for general filling of areas and for embankments
For the fill referred to in paragraphs 2.2.1 and 2.2.2, the material shall meet the
requirements of ASTM standard D 3282 for granular materials of groups A-1,
A-2-4, A-2-5 and A-3.
The use of material having maximum particle size greater than 75mm is not
allowed.
3.2.2 Material for Tank Foundations
3.2.2.1 Tank pad
a) Soil-aggregate mixture
For this fill, which is referred to under 2.2.3.1.a, the material shall meet the
requirements of ASTM D 1241.
b) Granular material
For this fill, which is referred to under 2.2.3.1.b, the material shall meet the
requirements of ASTM D 3282 for granular material of group A-1-a.
The use of material having maximum particle size greater than 75mm is
not allowed.
c) Sand
For this fill, which is referred to under 2.2.3.1.c, the sand shall consist of
lithoid, natural or crushed material, passing the No. 10 sieve (2.00mm)
and retained on the No. 200 sieve (0.075mm).
The sand shall be free from organic matter or clay, well graded, and
consist of hard particles (not coming from decomposed or gypsum rocks).
00-CA-E-10150

3.2.2.2 Ring
For these embankments, which are referred to under 2.2.3.2, the material shall
consist of coarse/finely crushed stone of well graded sizes between 10 and
70mm.
Crushed stone may be crushed rock or crushed pebbles.
Crushed stone shall be free of deleterious parts, have sharp edges (in any case
with predominance of crushed surfaces over rounded surfaces), and shall
neither be too elongated nor too flaky.
The weight percent loss due to abrasion shall not exceed 50, in accordance
with ASTM C 131 and C 535.
3.2.3 Material for Bund Walls, non-structural Backfilling and Filling
For this fill, which is referred to in paragraphs 2.2.4, 2.2.5 and 2.2.6, the
material shall meet the requirements of ASTM D 3282 for granular material of
groups A-1, A-2 and A-3, and for silt-clay materials of groups A-4, A-5 and A-6.
The use of material having particles greater than 75mm in size is not allowed.
3.2.4 Material for Replacing Unsuitable Material and for Concrete-Pavement

Foundations
For these particular types of filling, which are referred to in paragraphs 2.2.7
and 2.2.8, unless otherwise specified in the project documents, the materials to
be used shall be in accordance with ASTM D 1241.
00-CA-E-10150

4. FILLING WORKS
4.1 Setting Out
4.1.1 The contractor shall set out the works in accordance with the elevations and
alignments specified on construction drawings, with reference to the bench
marks fixed by the employer.
4.1.2 The contractor shall take account of deductions from finished levels due to the
thicknesses of trimming and topsoiling layers, road sub-bases, etc.
4.2 Preparation of Subgrade
4.2.1 The ground surface that shall support the first layer of fill shall be cleared of
topsoil and vegetation through soil stripping and removal.
4.2.2 Any facilities and equipment used during excavation, including propping for wall
support, etc., shall be removed from the excavation before and during
backfilling.
4.2.3 In the event of interruption of fill construction, the work can be resumed only
after removing the shrubs, bushes and vegetation that may have grown, and
after making the required furrows for connection of the new materials with those
previously employed.
4.2.4 If the subgrade is sloping more than 15%, stepped platforms shall be
constructed, with steps about 0.30 m in height and slope opposite to the ground
slope.
4.2.5 After topsoil removal, the subgrade shall be compacted to at least 90% of the
maximum dry density determined as per ASTM D 1557 (modified Proctor). The
water content of the material shall range between -3% and +5% the laboratory
value. The frequency of the compaction tests shall be as specified for the layer
supported (see table 4.3.5.2.a).
4.2.6 For plastic soils (in case they are affected by groundwater) the degree of
compaction of the subgrade may be reduced up to 85% of the maximum dry
density determined as per ASTM D 1557 (modified Proctor), if soil compaction
is difficult as pointed out by the tests made.
00-CA-E-10150

4.2.7 To preserve the fill from moisture (which may seep upwards due to capillary
forces from the subgrade) and from horizontal motion of water at the foot of the
fill, if the fill consists of earth material, the employer may request the contractor
to lay on the subgrade a dry material layer having a finished thickness of
200mm (300mm if gravel), consisting of crushed stone or gravel (size 10-
70mm), to be completed with drains if requested by the employer.
4.3 Method of Construction
4.3.1 Placing of Fills
4.3.1.1 Where groundwater is present, it shall be lowered to a level that does not affect
the placing and compaction of the layers, for at least 400mm.
4.3.1.2 The material shall be placed in regular layers so as to avoid particle

segregation, until obtaining - after compaction and settling - the finished work in
accordance with design sections and elevations.
Each layer shall have a suitable slope to permit quick removal of rain water, but
in any case the slope shall not be greater than 3%.
The best material available, whether from excavation or borrow pits, shall be
used for the top layers. In any case the employer reserves the right to establish
the laying sequence for the various materials on a case-by-case basis.
The larger size rock fragments shall be spread in the lower part of the fill, and
the smaller size fragments in the upper layers.
4.3.1.3 The contractor may start a new layer only after the underlying layer, finished
and compacted, has been accepted by the employer on the basis of the tests
made. Any deviation from the above shall be subject to the employer's prior
approval.
4.3.2 Methods and Equipment for Construction
4.3.2.1 On the basis of the materials properties and the analyses made, the contractor
shall propose to the employer specific methods and equipment for the required
filling; details of machinery shall be attached, as well as any results obtained
from previous experience on similar materials or specific trial tests.
4.3.2.2 Compaction of fill by water flooding or jetting shall not be used without the prior
specific written approval of the employer.
00-CA-E-10150

4.3.2.3 The required compaction degree shall be obtained using suitable equipment,
and shall also be reached in limited areas and/or adjacent to existing works or
foundations.
4.3.2.4 Compaction operations shall be continuous, from the outer edges of the area to
be compacted towards the centre, until the laid material has reached the
required compaction.
4.3.2.5 The moisture of the material used for each layer can be adjusted, if necessary
and after obtaining the employer's approval, by wetting with water using a
suitable sprinkler, or by drying or other treatment, according to the results of the
laboratory tests made in accordance with paragraph 3.1.4 above.
4.3.3 Thickness of the Layers
The loose material for each layer shall be laid so that after compaction the
thickness of each layer shall not exceed the value prescribed in table 4.3.3.a.
If compaction is performed manually using suitable equipment, the maximum

allowable thickness of the compacted layer is reduced to 100mm, unless
otherwise agreed with the employer.
4.3.4 Compaction Degrees for the Various Fills
The material placed shall be compacted to the degree expressed as a

percentage of the maximum dry density per ASTM D 1557 (modified Proctor)
established by table 4.3.4.a.
4.3.5 In situ Compaction Tests
4.3.5.1 The contractor shall carry out the necessary tests in accordance with point
4.3.5.2 for the determination of the optimum water content and the maximum
dry density in accordance with ASTM D 1557 (modified Proctor) and for in situ
determination of the water content and dry density in accordance with ASTM
D 1556.
The contractor shall maintain detailed records of the tests for the various
materials, a copy of which shall be handed over to the employer within one day
after the completion of the tests.
4.3.5.2 The frequency of the tests for in situ determination of dry density shall be at
least as specified in Table 4.3.5.2.a.
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4.5.3.3 If in situ dry density in two successive tests carried out on the laid and
compacted material is more than 105% of the dry density determined by the
laboratory test, the compaction degree obtained is not acceptable and retesting
is required.
4.5.3.4 The material to be compacted, during and after the compaction operations, shall
have a water content between -3% and +5% the laboratory optimum water
content in accordance with ASTM D 1557.
4.3.6 Finishing of Fills
Fills shall be finished with regular and flat slopes, well shaped and aligned
edges. During the work, and until work acceptance, the necessary cutting or
refilling shall be performed, as well as trimming and grading of the slopes, and
cleaning of any ditches.
4.3.7 Special Requirements for General Filling in Plant Areas
The employer may request that placing of fill in plant areas should be performed
in two stages.
During the first stage, filling is to be performed up to the level of top of

foundation base slab and/or the bottom level of the plant buried systems (this
level normally ranges between -1.20 m and -0.80 m from the finished grade
level).
During the second stage, after the construction of foundations and laying of
buried systems, the filling of areas is to be carried out up to the pavement
formation level.
This second stage is more complex because of the presence of foundations and
piping, and because its timing is determined by the construction schedule,
which the employer reserves the right to define as and when appropriate.
4.3.8 Special Requirements for Tank Bund Walls
As a general practice bund walls are not constructed in a single stage,

considering that openings must be left for access of materials and equipment
for mechanical erection of the tanks.
Completion of the bund walls shall be performed after completion of mechanical

erection.
00-CA-E-10150

4.3.9 Special Requirements for Borrow Pits within the Plant and/or Site Area
If the borrow pits are located inside the plant and/or site area, after obtaining the
employer's written approval, the contractor shall be responsible for avoiding soil
slips, stagnation of water, etc. during the works, and for meeting all special
regulations issued by the employer taking into account the actual
circumstances.
4.4 Tolerances
4.4.1 The tolerances of finished fills in respect of the dimensions and elevations
specified in the design drawings shall be as follows:
a) positioning of embankments and slopes : -150/+0mm

b) finished levels of embankments : -30/+30mm
The application of the above tolerances implies that the minimum specified
slopes are met.
4.4.2 The applicable tolerances for tank foundations before hydrotesting are as per
paragraph 4.4.1, except for:
a) finished levels of embankments : -30/+10mm.

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REFERENCED MAXIMUM THICKNESS OF

TYPE OF FILL
PARAGRAPH COMPACTED LAYER
GENERAL FILLING AND EMBANKMENTS 2.2.1 150mm
2.2.2
TANK FOUNDATIONS 2.2.3 150mm
BUND WALLS 2.2.4 250mm
NON-STRUCTURAL FILLING 2.2.5 300mm (filling)
2.2.6 500mm (backfilling of trench excavation)
LOCAL REPLACING 2.2.7 150mm
PAVEMENT FOUNDATIONS 2.2.8 150mm
Table 4.3.3.a
REFERENCED
TYPE OF FILL % OF MAXIMUM DRY DENSITY
PARAGRAPH
GENERAL FILLING AND EMBANKMENTS 2.2.1 95 %
2.2.2
TANK FOUNDATIONS 2.2.3 98%
BUND WALLS 2.2.4 90%
NON-STRUCTURAL FILLING 2.2.5 80%
2.2.6
LOCAL REPLACING 2.2.7 95%
PAVEMENT FOUNDATIONS 2.2.8 95%
Table 4.3.4.a
REFERENCED
TYPE OF FILL NUMBER OF TESTS FOR EACH LAYER
PARAGRAPH
GENERAL FILLING AND EMBANKMENTS 2.2.1 1 every 500 m²
2.2.2
TANK FOUNDATIONS 2.2.3 1 every 300 m²
BUND WALLS 2.2.4 1 every 1000 m²
NON-STRUCTURAL FILLING 2.2.5 1 every 1000 m²
2.2.6
LOCAL REPLACING 2.2.7 1 every 300 m²
PAVEMENT FOUNDATIONS 2.2.8 1 every 500 m²
Table 4.3.5.2.a
Each test shall consist of a set of three field density tests in accordance with
ASTM D 1556.
00-CA-E-10150

5. SURFACE FINISHING
5.1 Topsoiling
5.1.1 General
Slopes, road shoulders, traffic islands, etc., if required by the design and/or by
the employer, can be covered with topsoil having a thickness between 150mm
and 200mm.
5.1.2 Construction Method
5.1.2.1 The final design elevation of embankments shall be suitably reduced to allow for
subsequent placing of topsoil, which shall be properly levelled in accordance
with the design sections.
5.1.2.2 The required topsoil may be obtained from topsoil removed from the site or
elsewhere: in any case it shall ensure growing of the vegetation and shall be
subject to the employer's prior approval.
5.1.2.3 Topsoiling shall be carried out in horizontal strips to be compacted by suitable

equipment so as to avoid slips.
Proper measures (e.g. use of boards fixed by steel rods, etc.) shall be taken to
prevent the topsoil from slipping down the slopes.
5.2 Placing of Gravel Layer
5.2.1 A gravel layer, which is a form of finishing for non paved areas to be carried out
where required by the design and/or by the employer, shall be obtained by
means of a layer of fine crushed stone or gravel having a uniform, levelled
thickness of at least 50mm.
5.2.2 The fine crushed stone and fine gravel shall have a particle size between 10mm
and 25mm and shall be good quality, perfectly clean and free from foreign
matter.
Samples of the material shall be submitted to the employer for approval before
use.
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B4. ROAD WORKS
1. GENERAL
1.1.1 This paragraph defines the materials characteristics, the requirements and
construction methods for road works.
1.1.2 This paragraph is applicable to sub-bases, base courses and pavements of the
flexible type, concrete kerbs, guardrails, and traffic paints on road pavements.
1.2.1 This paragraph shall be used in conjunction with the contract documentation,
with any special requirements included in design specifications drawings and
paragraph B1/B3 of this specification.
1.2.2 Codes, Standards and Legislation
AI (Asphalt Institute) AI MS-1 Thickness design, AI MS-4 Asphalt Handbook
1.2.2.1 All materials, workmanship, testing and design (where applicable) shall be in
accordance with the latest edition of the codes and standards listed under
1.2.3.3., except where otherwise specified in this general specification or other
contract documents.
1.2.2.2 Notwithstanding the requirements of the above point, the applicable technical
legislation in force must be complied with.
1.2.2.3 AASHTO M 180 Specification for Corrugated Sheet Steel Beams for Highway
Guardrail
AASHTO M 248 Specification for Ready-Mixed White and Yellow Traffic

Paints
ASTM C 117 Test Method for Material Finer than 75-µm (No. 200) Sieve in
Mineral Aggregates by Washing
ASTM C 131 Test Method for Resistance to Degradation of Small-Size

Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine
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ASTM C 136 Test Method for Sieve Analysis of Fine and Coarse
Aggregates
ASTM C 150 Specification for Portland Cement
ASTM D 242 Specification for Mineral Filler for Bituminous Paving

Mixtures
ASTM D 422 Test Method for Particle-Size Analysis of Soils
ASTM D 490 Specification for Tar
ASTM D 558 Test Methods for Moisture-Density Relations of Soil-Cement

Mixtures
ASTM D 559 Test Methods for Wetting-and-Drying Compacted Soil-

Cement Mixtures
ASTM D 560 Test Methods for Freezing-and-Thawing Compacted Soil-

Cement Mixtures
ASTM D 692 Specification for Coarse Aggregate for Bituminous Paving

Mixtures
ATSM D 806 Test Method for Cement Content of Soil-Cement Mixtures
ASTM D 946 Specification for Penetration-Graded Asphalt Cement for

Use in Pavement Construction
ASTM D 977 Specification for Emulsified Asphalt
ASTM D 1073 Specification for Fine Aggregate for Bituminous Paving

Mixtures
ASTM D 1139 Specification for Aggregate for Single or Multiple Bituminous

Surface Treatments
ASTM D 1188 Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using Paraffin-Coated
Specimens
ASTM D 1241 Specification for Materials for Soil-Aggregate Sub-base,

Base and Surface Courses
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ASTM D 1369 Practice for Quantities of Materials for Bituminous Surface

Treatments
ASTM D 1557 Test Method for Laboratory Compaction Characteristics of

Soil Using Modified Effort (56,000 ft-lbf/ft³ (2,700 kN-m/m³))
ASTM D 1633 Test Method for Compressive Strength of Moulded Soil-

Cement Cylinders
ASTM D 2027 Specification for Cutback Asphalt (Medium-Curing Type)
ASTM D 2028 Specification for Cutback Asphalt (Rapid-Curing Type)
ASTM D 2397 Specification for Cationic Emulsified Asphalt
ASTM D 2399 Practice for Selection of Cutback Asphalts
ASTM D 2726 Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using Saturated Surface-
Dry Specimens
ASTM D 3203 Test Method for Percent Air Voids in Compacted Dense and
Open Bituminous Paving Mixtures
ASTM D 3381 Specification for Viscosity-Graded Asphalt Cement for Use in

Pavement Construction
ASTM D 3515 Specification for Hot-Mixed, Hot-Laid Bituminous Paving

Mixtures
ASTM D 3549 Test Method for Thickness or Height of Compacted

Bituminous Paving Mixture Specimens
ASTM D 3628 Practice for Selection and Use of Emulsified Asphalts
ASTM D 4318 Test Method for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM A53 Standard specification for pipe, steel Black and Hot dipped,
Zinc coated welded and seamless
ANSI A 21051 Ductile – Iron pipes, centrifugally cast, in Melted Moulds or

sand – lined Moulds for water or other liquids
ASTM C14, C76 Concrete pipe

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1.3 Definitions
1.3.1 Sub-grade
The surfacing plane of natural or backfilled ground, prepared and compacted,

which bears the loads transmitted by the paving layers.
1.3.2 Sub-base
A layer between the subgrade and the base course, or between the subgrade
and the concrete pavement.
1.3.3 Base Course
A layer placed on the subgrade or sub-base, forming the main element of the
pavement system.
1.3.4 Pavement
A structure suitable for supporting the vehicular design traffic and ensuring the
preservation of the base course and shape also in case of adverse weather
conditions.
1.3.5 Binder Course
A layer which is part of the pavement and is used as a connection between the
base course and the wearing course.
1.3.6 Wearing Course
A layer which is part of the pavement and is used for supporting the vehicular
traffic directly.
1.3.7 Surface Treatment
A type of pavement, used for direct support of vehicular traffic, made with the
application of bituminous material and subsequent placing of a layer of
aggregates. The applications may be repeated (double, triple).
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2. MATERIALS
2.1 Sub-bases
2.1.1 Sub-base using Earth Stabilised with Cement
2.1.1.1 This sub-base shall be made using a combination of soils with Portland cement
type I, in proportions to be established depending on the strength specified for
the sub-base.
2.1.1.2 The particle size determined in accordance with ASTM D 422, for soils to be
stabilised with cement, shall range within the limits specified in the following
Table 2.1.1.2.a:
Nominal sieve size Mass percent passing

75 mm 100
4.75 mm 50 - 100
0.425 mm 15 - 100
0.075 mm 0 - 50
Table 2.1.1.2.a
2.1.1.3 The plasticity characteristics of the material passing the 0.425mm sieve,
determined in accordance with ASTM D 4318, shall be as follows:
- liquid limit not greater than 40

- plasticity index not greater than 18.
2.1.1.4 The soil to be stabilised shall be free of vegetation and of any other foreign
matter.
The water for stabilisation shall be clear and free of detrimental impurities such
as oils, acids, alkalis, organic matter, etc.
2.1.2 Sub-base using Soil-aggregate Mixture
Quality, characteristics and particle size of materials shall be in accordance with

ASTM D 1241.
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2.2 Base Courses
2.2.1 Base Course using Bituminous Mixture
2.2.1.1 Quality, characteristics and particle size of materials shall be in accordance with
ASTM D 3515 for open mixtures.
2.2.1.2 The Marshall stability of the bituminous mixtures, determined in accordance

with ASTM D 1559, shall not be lower than 6 kN, with a flow value less than
5mm. The test temperature shall be equal to or 10°C higher than the laying
temperature.
2.2.2 Base Course using Soil-aggregate Mixture

ASTM D 1241.
2.3 Pavements
Concrete pavement shall be clarified in the following categories:
1. Heavy – Duty pavement:
The concrete thickness shall be minimum 250mm, reinforced with two

layers of 200 x 200 x 8 x 8mm fabric mesh.
2. Light – Duty pavement:
The concrete thickness shall be minimum 150mm, reinforced with one

layer of 200 x 200 x 8 x 8mm fabric mesh.
2.3.1 Binder Course using Bituminous Mixture
ASTM D 3515 for open mixtures.

4mm. The test temperature shall be equal to or 10°C higher than the laying
temperature.
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2.3.2 Wearing Course using Bituminous Mixture
ASTM D 3515 for dense mixtures.

3.5mm. The test temperature shall be equal to or 10°C higher than the laying
temperature.

ASTM D 1139 and D 1369.
2.4 Materials for Bituminous Mixtures
The materials to be used for bituminous mixtures shall be in accordance with

the following Standards, respectively:
− fillers ASTM D 242

− coarse aggregates ASTM D 692
− fine aggregates ASTM D 1073
− asphalts ASTM D 946 and ASTM D 3381
− emulsified asphalt ASTM D 977
− tars ASTM D 490.
2.5 Precast Concrete Kerbs
2.5.1 Precast concrete kerbs shall be manufactured in series, straight elements of

1000 and 500mm length and curved elements of various radii. The kerbs shall
have trapezoidal cross-section with a base of 150mm and minimum height
250mm, and external bevelled edge.
Suitable gully openings may be requested in some elements in order to convey

the rain water to the drainage pits, without obstruction or clogging.
The joint surfaces shall be flat and perpendicular to the sides so that the heads
of the individual elements can be perfectly joined with minimum gaps. The
elements may also be manufactured with groove-and-tongue joints.
2.5.2 All kerbs shall be undamaged, and non porous. The concrete mix shall be
homogeneous; the exposed surfaces shall be smooth and uniform.
2.5.3 The supply of kerb elements shall be subject to the employer's prior approval.
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2.6 Guardrails
Highway guardrails shall have the characteristics specified in AASHTO

Standard M180.
In particular, the beams shall have a useful length of 3.810 m, be W-beam

shaped, and have a nominal sheet thickness of 2.67mm.
Special pieces shall be provided for the guardrail ends.
Upright supports shall be made from steel sections MC 150x17.9 or equivalent,

1950mm long, made of steel ASTM A36.
All the steel parts shall be hot-dip galvanised with a minimum zinc amount of
550 g/m²; this value is to be intended as the quantity needed to zinc-coat both
faces of the surfaces.
2.7 Traffic Paints
The reflecting traffic paints covered by this specification shall be made using
materials with characteristics as per AASHTO Standard M 248.
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3. ROAD WORKS
3.1 Setting-out
The setting out of the works shall be carried out in accordance with the
elevations, alignments and bending radii specified on the drawings approved for
construction, with reference to bench marks established by the employer.
3.2 Sub-grades
The lower layer of the pavement system shall rest on the soil prepared and
compacted in accordance with the requirements of paragraph B4 of this
specification.
3.3 Tolerances
3.3.1 Road centre-line and edges as constructed shall be within a tolerance of ±

15mm from the design ones.
3.3.2 The finished surfaces of sub-base and base courses shall not differ from the
design shape by more than 10mm, to be checked with a rule 4500mm long,
placed in all directions. The tolerance shall be reduced to 5mm for binder and
wearing course.
3.3.3 The finished level of all points of the surface of each course shall be subject to
the following tolerances:
a) wearing courses + 5 mm
− 5 mm
b) binder courses + 0 mm
−10 mm
c) road base + 0 mm
−20 mm
d) sub-bases +10 mm
−20 mm
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3.4 Road Sub-bases
3.4.1 Sub-bases Stabilised with Cement
3.4.1.1 Preliminary tests
The following preliminary tests shall be performed by the contractor before the
commencement of the works and submitted to the employer for approval:
a) tests for the determination of the physical characteristics of soils:
− particle size analysis in accordance with ASTM C 117 and C 136

− liquid limit and plasticity index in accordance with ASTM D 4318
b) tests for the determination of the optimum soil-cement mixture and of the
minimum cement content necessary to achieve a degree of hardness
adequate to resist the field weathering:
− tests for the determination of the maximum density and optimum

moisture content of the soil-cement mixture in accordance with
ASTM D 558
− wetting and drying tests in accordance with ASTM D 559
− freezing and thawing tests in accordance with ASTM D 560.
3.4.1.2 Cement content and compressive strength
The cement content shall not be less than 3% by mass of the soil, determined in
accordance with ASTM D 806.
The compressive strength after 7 days curing shall be determined in

accordance with ASTM D 1633 on a series of 4 specimens compacted to the
maximum density as per ASTM D 558.
The average strength of the 4 specimens shall range within the reference
values 1.85 N/mm² and 4.85 N/mm², determined in accordance with method A
as per ASTM D 1633.
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3.4.1.3 Preliminary trial test
At least 14 days before the commencement of the works, the contractor shall
carry out a trial test on an area, whose location shall be agreed with the
employer, having a minimum length of 40 m and a minimum area of 200 m².
The materials, proportion of the mixtures, mixing and compaction method, and
equipment used for the trial test shall be used for the works, provided that the
laboratory test results have verified the conformance to the required
characteristics of the stabilised earth.
The values obtained in the trial area shall be used as terms of comparison for
the moisture content and minimum degree of compaction to be obtained during
the works.
3.4.1.4 Construction methods and requirements
The works must be executed only when the air temperature is higher than +4°C
and the weather is dry.
The stabilisation operations shall be performed in the following order:
- particle-size correction of the soil, if necessary

- homogenising of the soil
- shaping of the loose layer
- placing of the cement
- mixing soil with cement
- addition of water
- final mixing
- compaction and profiling.
The required quantity of cement shall be uniformly distributed on the surface.
The cement shall be placed only on the area that can be completed on the
same day.
No equipment, except for the equipment used for mixing, shall pass across the
area where the cement has been placed until the mixing of cement with soil has
been completed.
Soon after placing the cement, it shall be mixed with the soil by adding the
required water quantity. The mixture obtained shall then be laid on the whole
width of the area to be treated so as to prepare it for compaction.
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The moisture content of the mixture, based on dry mass, shall not be less than
the optimum prescribed during the whole working time; an allowable difference
of plus/minus 2% from the optimum moisture content required is permissible.
The uncompacted mixture shall be uniformly compacted to reach an in situ

density not lower than 95% of the maximum density obtained by the laboratory
test on the soil-cement mixture.
The operation time and consequently the number of passes shall be as

necessary to reach the required characteristics of the mixture and the specified
profiles and slopes, before the cement starts setting.
The thickness of the layer to be stabilised shall not be less than 75mm after
completion of compaction.
If the required thickness is more than 200mm, it shall be formed with two or
more layers, provided that the thickness of each finished layer ranges between
75 and 200mm.
If two or more layers are required, mixing of the materials "in situ" is allowed
only for the first bottom layer.
The thickness shall be as specified, with a tolerance of ± 3%.
At the end of the working day and at any break, a head board shall be used to
form a construction joint. The joint shall be finished so that work may be
resumed without the need for any further work.
Any suspension of work (for any reason whatsoever) lasting more than 30
minutes shall require the portion under construction to be remade by the
contractor at his own expense.
Traffic shall not be allowed for at least 7 days after the completion of the works;
proper measures shall be taken to protect the mixture from loss of moisture.
3.4.1.5 Protective layer of emulsified asphalt
If the layer of stabilised soil-cement remains exposed to the weather for long
periods, at the employer's request a protective layer of emulsified asphalt (in
accordance with ASTM D 977 or D 2397, and selected as per ASTM D 3628)
shall be applied at a rate of 1.00 kg/m².
The protective layer shall be applied after brushing and air-blowing, immediately
after compaction, using mechanical equipment operating outside the area of the
stabilised layer.
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3.4.1.6 In situ tests
The contractor shall perform the following tests and submit the results to the
employer for every 1000 m² of each completed layer, in accordance with ASTM
D 558:
− determination of the maximum density of the material in situ as compared

with the maximum laboratory density
− determination of in situ moisture content.
3.4.2 Road Sub-bases using Soil-aggregate Mixture
The preliminary tests for the physical characteristics of the mixtures, to be

carried out by the contractor before the commencement of the works and
submitted to the employer for approval, shall be those specified in ASTM D
1241, including in particular, but not limited to, the following:
− particle-size analysis in accordance with ASTM C 117 and C 136

− weight percent loss in accordance with ASTM C 131
− liquid limit and plasticity index in accordance with ASTM D 4318
− tests for the determination of modified maximum (optimum) dry density
and modified optimum water content, in accordance with ASTM D 1557.
The requirements of paragraph B4 of this specification and the requirements

specified here shall normally apply to construction methods.
The layer may be placed only after the employer has approved the subgrade.
Uncompacted material shall be placed in layers. The thickness of the finished

layer shall not exceed 200mm and shall be uniformly mixed before compaction,
so as not to show segregation of components.
Compaction shall be applied to the whole depth of the layer until obtaining an in
situ density not lower than the modified maximum (optimum) dry density.
The water content shall be within the range of optimum laboratory value minus
2 percent (-2%) and optimum laboratory value plus 2 percent (+2%). If the
material is too wet, it shall be adequately aerated or, in the opposite case, water
shall be added by means of sprinklers until the allowable values are reached.
00-CA-E-10150

Any remaking and corrective action that may be necessary to obtain uniform
surfaces shall be carried out promptly before the surface is compacted, so that
the new material added is incorporated in the layer below without excessive
crushing.
The operations shall be performed when the weather conditions (rain, snow,
frost, etc.) are not such as to damage the works. In the event of damage
caused by frost, excessive humidity, etc., the damaged layer shall be removed
and remade by the contractor at his own expense. The thickness shall be as
specified with a tolerance of plus/minus 5%.
The contractor shall carry out the following tests and submit the results to the
employer for every 1500 m² of surface area for each layer completed, in
accordance with ASTM D 1557:
− determination of the modified maximum dry density (modified) of the

material in situ as compared with that obtained by laboratory testing.
− determination of the modified in situ water content.
3.5 Roadbases
3.5.1 Base Course made with Bituminous Mixture
3.5.1.1 Determination of the job mix composition
The mixture compositions specified in ASTM D 3515 are a basis for the study of
the final job mix.
The contractor shall make trial tests on samples prepared with the various
components in order to define the job mix suitable for the traffic, the climatic
conditions, and the density of the aggregates used.
These tests shall be carried out by official testing laboratories in accordance

with the standards set out in ASTM D 3515, and shall be submitted to the
employer for approval before the commencement of the works. The following
information shall be provided in the documents, including but not limited to:
− particle size, maximum nominal dimension and density of the aggregates

− mix formula (aggregates, filler if any, content, type and degree of
penetration of the bituminous binding material)
− mixing times to be adopted
00-CA-E-10150

− Marshall stability and flow, in accordance with ASTM D 1559, showing the
temperature at which the test is performed.
The employer reserves the right to approve the test results and/or to have
further tests carried out; the employer's approval shall not relieve the contractor
from his responsibilities and obligations to meet the required characteristics for
the placed mixtures.
3.5.1.2 Subgrade preparation
The surface to be lined shall be cleaned by washing and blowing, in order to

have the subgrade free from foreign matter that may prevent proper adhesion of
the layers. The mixture may be placed only after the subgrade has been
approved by the employer.
Before placing the mixture, a prime coat of cutback asphalt (in accordance with
ASTM D 2027 or D 2028) shall be applied to the subgrade; the cutback asphalt
shall be selected in accordance with ASTM D 2399 at the rate of 1.2 l/m² and
spread by a spraying machine.
The prime coat shall be uniformly spread on the surface; the areas with
insufficient bituminous material shall be re-sprayed until reaching the required
uniformity.
The surfaces of the structures adjacent to the subgrade shall be adequately

protected to avoid spattering of bituminous material.
3.5.1.3 Preparation and spreading of bituminous mixture
The bituminous mixture shall be placed immediately after the application of the
prime coat.
The preparation of the bituminous mixtures shall be in accordance with ASTM

D 3515.
Any change in the job mix formula, concerning the particle size of the
aggregates (through the particle size analysis at the plant) and the content of
bituminous binding material (through extraction tests from the finished mixture)
shall not exceed the tolerances specified by ASTM D 3515.
The capacity of the machinery shall be proportioned to the construction

programs, so as to ensure drying and pulverisation of aggregates, heating of
the aggregates and bitumen to the required temperatures, checking of the
temperature reached and continuous monitoring of the exact composition of the
mixture.
00-CA-E-10150

The materials shall be spread using suitable pavers (except for very small
surfaces, subject to the employer's approval, where spreading is carried out
manually); the machines shall be in proper working order and equipped with
automatic levelling devices to achieve the required thicknesses, widths, profiles,
cambers and crossfalls, without causing segregation, surface defects, irregular
compaction, dragging and burning of material.
The materials shall be placed in layers having a thickness not less than twice
the max. nominal size of the aggregate; each compacted layer shall have a
thickness not greater than 150mm.
During spreading, particular care is needed in making longitudinal joints, which

are to be obtained preferably by prompt placing of a strip near the previous one
by means of 2 or more pavers. If this is not possible, the edge of the strip
already made shall be spread with emulsified asphalt (in accordance with ASTM
D 977 or D 2397) selected in accordance with ASTM D 3628, to ensure proper
jointing of the subsequent strip. If the edge appears to be damaged or rounded,
it shall be cut vertically using appropriate equipment. Overlapping of
longitudinal joints between the layers shall be made so that they are staggered
at least 200mm and do not fall within the route normally covered by the wheels
of the vehicles.
Transverse joints due to daily work interruptions shall always be made after
cutting and removal of the end portion previously carried out.
The surfaces of work resumption joints or of joints against walls shall be spread
with emulsified asphalt before laying the bituminous mixture.
The spreading of uncompacted material shall be made within the temperatures

specified by ASTM D 3515.
Each individual layer shall be placed as quickly as possible so that the adhesion
of the layers is not impaired. Any subsequent layer may be placed only after
the employer has approved the layer below.
The placing of the mixtures shall be interrupted in case of adverse weather

conditions (rain, sandstorms, etc.) that may affect the proper completion of the
works.
Compaction shall begin as soon as the mixtures are spread, and shall be
completed without interruption.
Compaction of each layer shall start before the bituminous mixture temperature
drops below 100°C and shall continue until reaching a density between 94%
and 100% of the density determined at the laboratory on the same day.
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The percent voids after compaction shall not exceed 8%.
The thickness shall be as specified with a tolerance of plus/minus 5%.
3.5.1.4 Tack coat
When more layers are placed, a tack coat of cutback asphalt (in accordance
with ASTM D 2028), selected in accordance with ASTM D 2399, shall be spread
on the lower layers at a rate of 0.35 l/m².
The tack coat shall be uniformly spread on the surface; the areas with
insufficient bituminous material shall be re-sprayed until reaching the required
uniformity.
The surfaces of the structures adjacent to the subgrade shall be adequately

protected to avoid spattering of bituminous material.
3.5.1.5 In situ tests of materials before spreading
The contractor shall carry out the following tests on the materials before placing
the bituminous mixture:
− particle size distribution check of the aggregates supplied to the site and
of the aggregates at the outlet of reclassification sieves (twice a week)
− check of the mixture composition (particle size of aggregates and content
of filler, if any; content of bituminous binding material) by taking the
mixture at the outlet of the mixer or of the storage hopper (twice a week).
− check of Marshall stability and flow, including determination of the
specimen density, as average values of 2 tests (once every working day).
3.5.1.6 In situ tests after spreading
Within 24 hours of the spreading of the bituminous mixture, the contractor shall
take core samples having minimum diameters 150mm, at locations selected by
the employer. The frequency of sampling is 1 sample every 1000 m²
performed, but not less than 2 samples every working session.
From the samples taken, the following tests shall be carried out and the results
shall be submitted to the employer:
− check of in situ density of the mixture, determined in accordance with

ASTM D 1188 or D 2726, whichever is applicable
− check of percent voids after compaction, determined in accordance with
ASTM D 3203
− check of the thickness of the layer in accordance with ASTM D 3549.
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3.5.2 Base Course made with Soil-aggregate Mixture
The provisions of para 3.4.2.1. shall apply.
The provisions of para 3.4.2.2. shall apply, except that the thickness of each
finished layer shall not exceed 150mm.
3.6 Paving
3.6.1 Binder Course
The provisions of para 3.5.1.2. shall apply, taking into account that the prime
coat is not necessary if the subgrade is made of bituminous mixture; in this case
a tack coat of cutback asphalt shall be applied, as described at para 3.5.1.4.
The provisions of para 3.5.1.3. shall apply, with the following additional
requirements.
The mixture shall be placed immediately after the prime coat or tack coat has
been applied whichever is applicable.
The material shall be spread in one layer having a minimum thickness of 40mm.
Compaction shall start before the bituminous mixture temperature drops below
107°C and shall continue until reaching a density between 95% and 100% of
the density determined at the laboratory on the same day.
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The mixture shall not be placed when the atmospheric temperature is below
5°C.
The thickness shall be as specified with a tolerance of ± 10%.
The provisions of para 3.5.1.6. shall apply, except for the sampling frequency,
which is 1 sample every 750 m² carried out, but not less than 2 samples every
working session.
3.6.2 Wearing Course
The provisions of para 3.5.1.1 shall apply.
The provisions of para 3.5.1.2 shall apply, taking into account that the prime
coat is not necessary if the subgrade is made of bituminous mixture; in this case
a tack coat of cutback asphalt shall be applied, as described at para 3.5.1.4.
The provisions of para 3.5.1.3 shall apply, with the following additional
requirements:
The mixture shall be placed immediately after the prime coat or tack coat has
been applied whichever is applicable.
The material shall be spread in one layer having a minimum thickness of 30mm.
Compaction shall start before the bituminous mixture temperature drops below
107°C and shall continue until reaching a density between 98% and 100% of
the density determined at the laboratory on the same day.
The mixture shall not be placed when the atmospheric temperature is below
5°C.
00-CA-E-10150

The thickness shall be as specified with a tolerance of ± 10%.
The provisions of para 3.5.1.6. shall apply, except for the sampling frequency,
which is 1 sample every 500 m² carried out, but not less than 2 samples every
working session.
This Specification defines the following types of surface treatments, to be

performed in accordance with ASTM D 1369:
− triple layer
− double layer
− single layer.
The aggregates and bituminous materials (type, grade, quantity) indicated in the
above-mentioned Standard are a basis for the study of the job specification for
surface treatment, to be submitted by the contractor to the employer for
approval before the commencement of the works. The specification shall be
completed by the tests on the materials, as specified in ASTM D 1369.
The surface to be finished shall be previously cleaned by washing and blowing,

in order to have the subgrade free from any foreign matter that may prevent
proper adhesion of the courses.
The treatment may be applied only after the subgrade or lower layer has been
approved by the employer.
The materials shall be placed in the quantities and with the characteristics
provided in the job specification approved by the employer.
Subsequent rolling shall be performed until obtaining an even and uniform

surface.
In the case of double or triple layer, the subsequent layers shall be performed
using the same methods as described above.
00-CA-E-10150

3.7 Concrete Kerbs
3.7.1 The kerbs shall be placed before completing the rolling of the base course and
before placing the bituminous mixture pavement.
The kerbs shall be placed on a base of lean concrete having a minimum

specified strength f’c (on cylindrical specimens) of 150 kg/cm2, a thickness not
less than 100mm, and adequate width to allow the construction of the
necessary support to ensure the stability of the individual elements also in case
of accidental impact.
3.7.2 The elements shall be placed in accordance with the specified alignments and
planes, so that the kerb protrudes at least 120mm above the finished pavement
level.
For straight roads, straight elements 1 m long shall be used as far as possible.
For roads with bending radius 8 m or less, curved elements of appropriate

radius shall be used. For roads with bending radius above 8 m, straight
elements 500 m long shall be used.
The joints shall be sealed, minimising the gaps, using fine cement grout and
subsequently pointed.
After placement, the elements shall be well aligned with a maximum deviation of
3mm every 3 m of length.
3.8 Guardrails
The uprights shall be embedded in concrete foundations or driven into the

ground according to design requirements.
The supports shall be driven into the ground by means of a hammer to a depth
of at least 1200mm to ensure full stability of the individual elements of the
guardrail also in case of slight accidental impact by vehicles.
Any foundations shall protrude 50mm from the finished pavement level and/or
from the road shoulder, and shall be made with concrete having a specified
strength on cylindrical specimens of 250 kg/cm2.
The uprights shall be installed in accordance with the elevations, distances and
alignments specified in the design drawings.
00-CA-E-10150

The guardrail beams shall be joined at the supports, and the two beams shall
overlap at least 300mm.
Each section of the guardrail shall end up with properly shaped curved ends.
The beams shall be fastened to the supports so that the minimum distance from
the ground level shall be 300mm.
The necessary bolts, nuts, washers, plates, end connections, spacers, etc.,
shall be used for installation.
Reflectors shall be placed every 8 m.
3.9 Traffic Paints (reflecting type)
Traffic paints on road pavements shall be in accordance with the employer's

directives with regard to the location and symbols of continuous or dashed lines,
signs, text, arrows and other symbols, using white or yellow paint according to
the project requirements.
The paint applied shall have a minimum thickness of 0.38mm. The reflecting
spheres shall be spread on the fresh paint film at a rate of 600 kg every m³ of
paint.
00-CA-E-10150

B5. SEWERS AND DRAINS
1. GENERAL
1.1.1 This paragraph defines the materials, work methods and testing of sewers and
drains, with reference to U.S. codes and standards.
1.1.2 This paragraph applies to reinforced and nonreinforced concrete pipes, vitrified
clay, cast iron and PVC pipes, as well as works or products such as septic
tanks, cast iron covers and gratings, earth and concrete channels, and cable
ducts.
1.2.1 Codes and Standards
The latest edition of the following codes and standards:
ANSI C11 Rubber Gasket Joints for Ductile-Iron and Gray-Iron Pipe
and Fittings for Water
ASTM A 746 Specification for Ductile Iron Gravity Sewer Pipe
EN 124 Gully Tops and Manhole Tops for Vehicular and Pedestrian
Areas - Design requirements, type testing, marking
ASTM C 14M Specification for Concrete Sewer, Storm Drain and Culvert
Pipe
ASTM C 76M Specification for Reinforced Concrete Culvert, Storm Drain

and Sewer Pipe
ASTM C 425 Specification for Compression Joints for Vitrified Clay Pipe
and Fittings
ASTM C 443M Specification for Joints for Circular Concrete Sewer and
Culvert Pipe, Using Rubber Gaskets
ASTM C 700 Specification for Vitrified Clay Pipe, Extra Strength, Standard
Strength, and Perforated
00-CA-E-10150

ASTM D 1785 Specification for Poly Vinyl Chloride (PVC) Plastic Pipe -
Schedules 40, 80, and 120
ASTM D 3139 Specification for Joints for Plastic Pressure Pipes Using
Flexible Elastomeric Seals
ASTM F 477 Specification for Elastomeric Seals (Gaskets) for Joining

Plastic Pipe
ASTM F 512 Specification for Smooth-Wall Poly Vinyl Chloride (PVC)

Conduit and Fittings for Underground Installation
ASTM F 789 Specification for Type PS-46 Poly Vinyl Chloride (PVC)
Plastic Gravity Flow Sewer Pipe and Fittings
00-CA-E-10150

2. MATERIALS
2.1.1 All pipes and complementary elements shall be supplied free from defects,
cracks, broken parts and discontinuity. The internal and external surfaces shall
be smooth and even.
Linings shall be adherent and proof against crumbling or flaking.
2.1.2 All pipes shall be marked as required by the standards.
2.1.3 Material supplies shall be accompanied by certificates of conformance

(including tests) showing compliance with the standards when required.
2.2.1 Non-reinforced Concrete Piping
Pipes and fittings shall have dimensions, dimensional tolerances and

requirements corresponding to those established in ASTM C 14M for Class 3.
Elastomeric seals shall conform to ASTM C 443M.
Pipes shall have a circular section with bell-and-spigot-joints.
2.2.2 Reinforced Concrete Piping

requirements all as in ASTM C 76M for the designation "Class IV - Wall C",
unless averification is made according to AASHTO “Standard Specification for
Highway Bridges” Section 17 to demonstrate that a lower class can be
applicable.
In case of pipes subjected to exceptional traffic loads, also Class IV shall be
verified according to the same method.
Elastomeric seals shall conform to ASTM C 443M.
Pipes shall be have a circular section bell-and-spigot joints.

00-CA-E-10150

2.2.3 Vitrified Clay Piping
Pipes, fittings and the related junction systems shall have dimensions,
dimensional tolerances and requirements corresponding to those established in
ASTM C 700.
The junction shall be provided with rubber ring gaskets , in accordance with
ASTM C 425.
Pipes shall have a circular section and bell-and-spigot joints.
The pipes and fittings shall be provided with an internal lining of a ceramic
glaze.
The products shall be made by the mixing and subsequent oven baking (at a
vitrification temperature of approximately 1100-1150 °C) of a paste of clays
(plastic clays, kaolin, etc.) and aggregate.
2.2.4 Ductile Iron Piping

requirements corresponding to those established in ASTM A 746 covering
ductile iron pipes for gravity flow sewers.
Elastomeric seals shall conform to ANSI C 111.
Pipes shall have a circular section with bell-and-spigot joints designed for rapid
elastic connections.
Pipes shall be lined internally with a layer of cement mortar and coated
externally with an asphaltic layer.
The pipes shall be produced by the centrifugation casting process.
2.2.5 Rigid (unplasticised) Polyvinyl Chloride (PVC) Pipes for Underground

Sewer Pipes

requirements all as in ASTM F 789 for series T-1.
Elastomeric seals shall conform to ASTM F 477.
Pipes shall have a circular section with bell-and-spigot joints.
The products shall be made of a rigid PVC base compound, plus only the
additives required to facilitate their fabrication.
00-CA-E-10150

2.2.6 Rigid (unplasticised) Polyvinyl Chloride (PVC) Pipes for Pressure Lines

requirements all as in ASTM D 1785 for pipes made with rigid PVC 2116 -
Schedule 40.
Elastomeric seals shall conform to ASTM D 3139.
Pipes shall have a circular section and joints for an elastomeric ring gaskets.
The products shall be made of rigid PVC base compound, plus only the
additives required to facilitate their fabrication.
2.2.7 Rigid (unplasticised) Polyvinyl Chloride (PVC) Pipes for Cable Protection
in Road Crossings

requirements all as in ASTM F 512 for type EB 20.
Pipes shall have a circular section with bell-and-spigot, click-on type.
The products shall be made of unplasticised polyvinyl chloride base mixtures,

plus only the additives needed to facilitate their fabrication.
2.2.8 Septic Tanks
Septic tanks shall be prefabricated type either a circular or rectangular cross-

section, made of reinforced concrete having a minimum specified strength on
cylindrical specimens of 250 kg/cm2.
They shall be suitable for clarifying sanitary waste waters by a process,

disintegration and gassification of the decanted solids by means of biological
fermentation. They shall ensure the discharge of non-putrescent, inodorous
waters with a low bacteria content and shall reduce the volume of solids to a
minimum.
The type of septic tanks supplied shall be subject to approval by the employer,
after the Contractor has submitted adequate documentation to prove their
quality and conformity to local and/or national rules, regulations and laws.
00-CA-E-10150

2.2.9 Cast Iron Covers and Gratings
Covers and gratings shall have characteristics conforming to EN 124 code or

the equivalent.
The covers and gratings, and their frame, shall be made of grey cast-iron and
shall remain steady with pedestrian or vehicle traffic.
Covers shall bear an indication of the nature of the service (sewer, electric
cables, drinking water, etc.).
Covers, whether air-tight or not, and grating shall have a size and a bearing
capacity class that will be in keeping with their location and purpose as defined
by the employer in the construction drawings and/or specifications.
The bearing class indicated by the employer as light shall be resistant to a load
test of 125 kN, while the class indicated as heavy shall be resistant to a load
test of 250 kN.
Gratings shall permit complete drainage, in case of rain, of the of the paving
sector relevant the drain pit.
2.2.10 Concrete Channels
Channels may be required with a rectangular or trapezoidal cross-section,

either precast or cast in situ with reinforced concrete having a specified strength
on cylindrical specimens of 250 kg/cm2 using aggregate of an appropriate
particle size gradation and reinforcing steel or electrically welded wire fabric.
The materials and work methods shall conform to the provisions of paragraph
B5 of this specification.
They shall show visibly smooth surfaces free from cracks and/or broken parts,
porosity and burrs.
Individual elements shall have a maximum length of 6 m.

00-CA-E-10150

3. WORK METHODS
3.1.1 Pipelines shall be laid in accordance with the positions and elevations indicated
on the project drawings.
The method of executing the work must take into account any particular
requirements stated by the piping manufacturer.
Any variation for any reason whatsoever shall be subject to prior approval by
the employer.
3.1.2 Normally pipe of the maximum possible lengths shall be used so as to minimise
the number of joints. Before laying, all the pipeline elements (pipes, joints and
fittings) shall be carefully inspected, checked and cleaned, both internally and
externally, paying particular attention to the pipe ends. Any defective elements
that may damage the quality or function of the work shall be rejected and
replaced.
3.1.3 As regards lifting, laying and handling in general of pipes (in trench, on
embankments and on bearing supports), the utmost care shall be taken using
equipment appropriate to the type and diameter of the pipes, taking all the
necessary measures to avoid breakage, cracks and/or damage in general to the
material forming the piping and its coating (if any).
3.1.4 The laying operations shall be carried out so as to prevent any detritus or
foreign matter of any kind from getting inside the pipeline. Laying shall be made
on a smooth level bed. Any unevenness capable of damaging the pipe or
coating shall be eliminated. Under no condition shall stones, bricks or other
discontinuous supports be used to adjust the position of pipes inside the trench.
The laying surface shall assure a perfectly continuous support.
Pipes damaged during laying shall be repaired so as to restore them to perfect

condition. Otherwise they shall be removed and replaced if they damage the
quality and functionality of the work.
3.1.5 Pipe ends and fittings to be joined and gaskets, if any, must be perfectly clean.
Joints shall assure continuous water tightness as well as the static behaviour
required by the design and they shall be made in conformity with the
construction specifications depending on the type of pipe and joint used and the
operating pressure.
00-CA-E-10150

3.1.6 On completion of the pipe jointing operation, the section of pipeline concerned
shall be subjected to a hydraulic test using the pressure, duration and methods
described in section 4 and/or those established in the project
drawings/specifications. The hydraulic test will be repeated after final backfilling
of the pipeline.
3.1.7 After successful performance of the water tightness test, the haunch and final
backfilling are made using the excavation and/or selected material and/or
quarry material according to the type of pipe, conforming to the requirements of
paragraph B3 "Fill". Whenever required the pipe laying bed and haunch may be
in concrete made using the material and methods established by paragraph
B1"Concrete works".
3.1.8 The piping installation method (laying, material for laying bed and partial and/or
total haunch, type of joint, sequence and materials) shall be according to the
methods described and/or required in the project drawings/specifications and
manufacturer's instructions.
3.2.1 Rigid (unplasticised) PVC Pipes for Cable Protection in Road Crossings
These pipes shall be spaced as shown in the drawings, so that concrete can be
placed between them and pipes are not in contact with each other. The pipes
shall also be suitably fastened so that no pipe lifting and/or movements occurs
during pouring of the concrete.
3.2.2 Precast Septic Tanks
A layer of lean concrete having a minimum cylindrical specified strength (f’c) of

150 kg/cm2 shall be placed on the bottom of the excavation to form a support for
the septic tank.
All the elements installed shall be free from cracks or any kind of breakage to
avoid leakage of foul sewer water into the ground.
Starting with the bottom ring, all the other elements shall then be mounted
according to the manufacturer's instructions, and care shall be taken to seal the
joints, after they have been wetted with a suitable neat cement grout, so as to
achieve water tightness.
The inlet and outlet openings shall be positioned in the correct order having
already established the gradient and the incoming and outgoing elevations of
the pipes, as indicated on the design drawings.
00-CA-E-10150

No other inlets and outlets shall be made, but those prearranged by the
manufacturer shall be used.
Septic tanks shall be filled with water before being placed in service.
Before utilisation septic tanks shall be subjected to a water tightness test

according to the provisions of section 4.
3.2.3 Cast Iron Covers and Gratings
Frames shall be inserted in pit or basin cover slabs during the construction
phase. Frames shall be positioned so that their upper edge is flush with the
surrounding finished level.
After installation, gratings or covers shall remain steady under the action of the
external loads and shall be easy to lift using the appropriate tools provided.
3.2.4 Drainage Channels
Drainage channels may be excavated and shaped directly in the earth if this is
permitted by the nature of the soil, or made of precast or cast-in situ concrete
elements.
a) Earth channels
They shall be excavated and shaped in the earth according to paragraph

B4, with the sections and gradients indicated in the project drawings.
For protection of the walls and bottom, an application of a protective layer

of cut-back asphalt may be required according to the requirements of
paragraph B4 "Road works".
b) Concrete channels
The concrete elements shall be placed on a layer of lean concrete having

a minimum cylindrical specified strength of 150 kg/cm2, according to the
position and gradients indicated on the design drawings.
Each element shall be perfectly aligned with the previous one, paying
particular attention to the bottom which shall not show any projecting parts
or steps.
The joints shall be made by a first layer of 15mm thick polystyrene and a
seal of 15 x 15mm section using a thixotropic material resistant to
hydrocarbons, after insertion of a backing cord.
00-CA-E-10150

3.2.5 Sandbedding for Laying and Covering of Electrical, Telephone and

Instrument user Cables
Cables for the above-mentioned users shall be laid and protected by a layer of
medium to fine sand having a particle size of 0.075-2mm, free from waste
matter, organic substances and/or material that could damage the sheath
and/or the cables laid.
A layer of levelled, compacted sand shall be laid on the bottom of the trench,
generally at a depth varying between 0.50 and 1.00 m. After laying of the
cables, a sand covering and/or protection layer shall be laid and compacted
taking care not to damage the cables laid.
Tiles or slabs made of concrete or other material shall be installed above the
final sand layer to indicate the presence of the cables.
The route, thickness, and laying sequence of the sand layers shall conform to
the methods described and/or established in the project drawings/specifications.
00-CA-E-10150

4. DRAIN ACCEPTANCE TEST
4.1.1 The test shall be performed on the whole and individual pipeline sections,
putting under pressure the sewer sections between one pit and another, before
beginning the backfilling and haunching activity, in order to test the
watertightness, good condition and reliability of the joint system and of the
piping elements. Short secondary branches may be tested together with the
header to which they are connected. Long secondary branches shall be tested
separately by inserting a temporary partition baffle at the connection point with
the mains.
4.1.2 The methods and requirements for the water tightness test of reinforced
concrete pits, tanks and basins are described in paragraph B4 "Concrete
works".
4.2 Particular Requirements
4.2.1 The test shall be performed by filling the whole section with water containing a
dye (aniline) to highlight any leakage.
4.2.2 Filling shall be performed so that the piping is subjected to a minimum pressure
of 0.15 bar and a maximum pressure of pressure of 1.5 bar. In the case of
pressure lines the test value is established in the project drawings and/or
specifications, depending on the operating pressure.
For this purpose, the two ends of the piping section to be tested must be closed
so that the water head at the highest point is equal to at least 1.5 m calculated
from the piping centreline, and maximum 5 m at the lowest point, taking due
account of the gradient.
4.2.3 The pipe ends shall be plugged preferably in a pit at the chamber walls to avoid
excessive tensile stress inside the pipe, especially if a plug is closed using an
elastomeric ring.
Suitable devices to remove the air inside the siphons shall be installed to permit
complete filling of the piping.
00-CA-E-10150

4.2.4 After at least 12 hours have elapsed to allow complete soaking of the joints and
pipe elements (especially for concrete piping) the original water level, which has
dropped due to soaking, must be restored. After an additional period of at least
30 minutes, a pipe-by-pipe and joint-by-joint inspection of the entire sewer
branch shall be performed. If no leakage or water infiltration is detected during
these 30 minutes, the test is considered successful.
In the case of pipe lines made of reinforced or plain concrete, slight sweating on
the external surface of the pipes is not considered a leak and does not
invalidate the successful result of the test, provided the extension of moist
surface on each pipe does not exceed 20% of the total external surface.
4.2.5 Every defect detected shall be definitely eliminated, even if this requires the
actual replacement of the element involved. These operations shall be carried
out by the contractor at his own expense. On completion of the repairs and/or
replacements, the whole test shall be repeated.
4.2.6 Only after successful testing may the work of piping backfilling or protection be
started.

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Client: Document No.

NICO Second Stage of Development

Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 1 of 103 Rev.: 2

2 Issued for Construction V.Moradi B.Hoseinzadeh N.Soia G.Lorio 15.08.06

ENI Iran B.V NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )

Second Stage of Development

Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 2 of 103 Rev.: 2

1.3 Symbols and Abbreviations

2.3 Mixing Water

2.6 Anchor Bolts

3.1 Grades of Concrete

3.3 Consistency and Workability

3.4 Mix Proportioning

4.1 Blinding Concrete

4.4 Joints and Embedded Items

4.5 Production of Concrete

4.6 Placing of Concrete

ENI Iran B.V NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )

Second Stage of Development

Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 3 of 103 Rev.: 2

4.7 Finished Surfaces

4.8 Concrete Curing, Protection and Patching

4.10 Special Constructions

4.11 Concreting in Hot Weather

5.1 Pre-placement Checks

5.2 Placement Checks

5.3 Post-placement Checks

5.4 Field Tests

5.5 Tightness Test for Basins and Pits

6.1 Documentation for the Material Prequalification

6.2 Mix Design Documentation

6.3 Other Documentation

1.2 Reference Documents

1.3 Definition of Excavation Types

1.4 Definitions of Excavation According to the Soil Nature

3.1 Employer's Requirements and Obligations

3.2 Contractor's Obligations

ENI Iran B.V NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )

Second Stage of Development

Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 4 of 103 Rev.: 2

3.3 Activities Subject to Approval

3.4 Use of Excavation Materials

1.2 Reference Documents

2.1 Fill according to the source of materials

2.2 Fill According to Destination

3.1 General Requirements

3.2 Special Requirements for Material from Borrow Pits

4.1 Setting Out

4.2 Preparation of Subgrade

4.3 Method of Construction

5.2 Placing of Gravel Layer

1.1 Scope and Field of Application

1.2 Reference Documents

ENI Iran B.V NATIONAL IRANIAN OIL COMPANY ( N.I.O.C )

Second Stage of Development

Plant Location: DARQUAIN OIL FIELD, IRAN Sheet 5 of 103 Rev.: 2

2.2 Base Courses

2.4 Materials for Bituminous Mixtures

2.5 Precast Concrete Kerbs

2.7 Traffic Paints

3.4 Road Sub-bases

3.7 Concrete Kerbs