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    This document contains the table of contents for a quality control specification (QCS) for a construction project. It lists 22 sections that will be included in the specification, covering topics such as general requirements, quality assurance and control, ground investigation, foundations, concrete, roadworks, drainage works, mechanical and electrical equipment, instrumentation and health and safety. The level of detail provided in the table of contents gives an overview of the scope and breadth of quality standards that will be required for the project.

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    This document contains the table of contents for a quality control specification (QCS) for a construction project. It lists 22 sections that will be included in the specification, covering topics such as general requirements, quality assurance and control, ground investigation, foundations, concrete, roadworks, drainage works, mechanical and electrical equipment, instrumentation and health and safety. The level of detail provided in the table of contents gives an overview of the scope and breadth of quality standards that will be required for the project.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    36K views4,571 pages

    QCS 2014 PDF

    Uploaded by

    calvente27
    This document contains the table of contents for a quality control specification (QCS) for a construction project. It lists 22 sections that will be included in the specification, covering topics such as general requirements, quality assurance and control, ground investigation, foundations, concrete, roadworks, drainage works, mechanical and electrical equipment, instrumentation and health and safety. The level of detail provided in the table of contents gives an overview of the scope and breadth of quality standards that will be required for the project.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 4571

    QCS 2014 Contents Page 1

    CONTENTS

    SECTION 1 GENERAL
    Part 1 Introduction
    Part 2 Use and Maintenance of the Site
    Part 3 Site Access and Entry onto the Site
    Part 4 Protection
    Part 5 Interference
    Part 6 Project Meetings
    Part 7 Submittals

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    Part 8 Building Demolition

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    Part 9 Materials

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    Part 10 Occupational Health and Safety
    Part 11 Engineers Site Facilities
    Contractors Site Facilities
    Part 12
    Part 13 Setting Out of the Works ta
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    Part 14 Temporary Works and Equipment
    Part 15 Temporary Controls
    Part 16 Traffic Diversions
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    Part 17 Project Co-ordination


    Part 18 Other Contractors
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    Part 19 Regulatory Requirements


    Part 20 Clearance of the Site
    er

    Part 21 Final Inspection and Handover Procedures


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    Part 22 New Technologies and Innovations


    Part 23 Design and Supervision Consultant Quality Requirement
    Part 24 Construction Dewatering
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    SECTION 2 QUALITY ASSURANCE AND QUALITY CONTROL


    Part 1 General
    m

    Part 2 Submittals
    Part 3 Contractors Quality Personnel
    Part 4 Document and Data Control
    Part 5 Quality Records
    Part 6 Quality Audits
    Part 7 Inspection And Test
    Part 8 Materials
    Part 9 Nonconformance Monitoring
    Part 10 Laboratories
    Part 11 Site Meetings And Reports
    Part 12 Failure By The Contractor To Meet Acceptable Quality Performance
    Part 13 Suspension of Work
    Part 14 APPENDIX A Sampling and Testing Frequencies
    Part 15 APPENDIX B Templates
    (Contractors Project Quality Plan Template, Contractors Inspection And Test
    Plan Template, and Quality Non-conformance Template)
    QCS 2014 Contents Page 2

    SECTION 3 GROUND INVESTIGATION


    Part 1 General
    Part 2 Boreholes
    Part 3 Pits and Trenches
    Part 4 Soil Sampling
    Part 5 in-Situ Testing, Instrumentation and Monitoring
    Part 6 Laboratory Testing

    SECTION 4 Foundations and Retaining Structures


    Part 1 General Requirements for Piling Work
    Part 2 Concrete Works for Piling

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    Part 3 Shadow Foundations

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    Part 4 Deep Foundations
    Part 5 Retaining Structures

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    SECTION 5 CONCRETE
    Part 1 General
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    Part 2 Aggregates
    Part 3 Cementitious Materials
    Part 4 Water
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    Part 5 Admixtures
    Part 6 Property Requirements
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    Part 7 Concrete Plants


    Part 8 Transportation and Placing Of Concrete
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    Part 9 Formwork
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    Part 10 Curing
    Part 11 Reinforcement
    Part 12 Joints
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    Part 13 Inspection and Testing Of Hardened Concrete


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    Part 14 Protective Treatments for Concrete


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    Part 15 Hot Weather Concreting


    Part 16 Miscellaneous
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    Part 17 Structural Precast Concrete


    Part 18 Prestressed Concrete
    Part 19 Testing of Water Retaining Structures
    Part 20 Personnel Qualifications and Certification

    SECTION 6 ROADWORKS
    Part 1 General
    Part 2 Site Clearance
    Part 3 Earthworks
    Part 4 Unbound Pavement Materials
    Part 5 Asphalt Works
    Part 6 Concrete Road Pavements
    Part 7 Asphalt Plants
    Part 8 Recycled and Stabilised Road Materials
    Part 9 Recycled Aggregate for Roadworks
    QCS 2014 Contents Page 3

    Part 10 Vehicle Crash Barriers


    Part 11 Kerbs, Footways and Paved Areas
    Part 12 Fencing
    Part 13 Traffic Signs, Markings and Studs
    Part 14 Works in Relation To Services
    Part 15 Road Lighting
    Part 16 Traffic Signals
    Part 17 Road Drainage
    Part 18 Geosynthetics
    Part 19 Miscellaneous

    SECTION 7 GREEN CONSTRUCTIONS


    Part 1 Introduction

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    Part 2 Global Sustainability Assessment System - GSAS

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    Part 3 Energy

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    Part 4 Water [W]
    Part 5 Indoor Environment
    Part 6 Cultural and Economic Value
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    SECTION 8 DRAINAGE WORKS
    Part 1 General
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    Part 2 Earthworks
    Part 3 Pipes and Fittings Materials
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    Part 4 Pipeline Installation


    Part 5 Valves, Penstocks and Appurtenances
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    Part 6 Miscellaneous Metal Works


    Part 7 Miscellaneous GRP Works
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    Part 8 Protective Coatings and Painting


    Part 9 Trenchless Pipeline Construction
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    Part 10 Pipelines Cleaning and Inspection Survey


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    Part 11 Sewer Rehabilitation


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    Part 12 Vacuum Sewerage System


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    SECTION 9 MECHANICAL AND ELECTRICAL EQUIPMENT


    Part 1 General
    Part 2 Submersible Pumps
    Part 3 Centrifugal Pumps (Dry Well)
    Part 4 Centrifugal Pumps (Split Casing)
    Part 5 Archimedian Screw Pumps
    Part 6 Surge Control System
    Part 7 Lifting Equipment
    Part 8 Electric and Pneumatic Actuators
    Part 9 Odour Control Equipment-Carbon Type
    Part 10 Odour Control Equipment-Scrubber Type
    Part 11 Screening Equipment
    Part 12 Grit Removal Equipment
    Part 13 Aeration Equipment
    Part 14 Air Blowers and Compressors
    QCS 2014 Contents Page 4

    Part 15 Settlement Tank Equipment


    Part 16 Tertiary Treatment Granular Filters
    Part 17 Sludge Thickening and Dewatering Equipment
    Part 18 Mixers and Stirrers
    Part 19 Chlorination Plant Equipment
    Part 20 Washwater Systems
    Part 21 Miscellaneous Equipment
    Part 22 Ventilation Systems

    SECTION 10 INSTRUMENTATION, CONTROL AND AUTOMATION


    Part 1 General
    Part 2 Telemetry/SCADA
    Part 3 Primary Elements
    Part 4 Panel Mounted and Miscellaneous Instruments

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    Part 5 Control Panels and Control Room Hardware

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    SECTION 11 HEALTH & SAFETY
    Part 1 Regulatory Document
    Part 2
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    Safety and Accident Prevention Management / Administration System
    (SAMAS)
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    SECTION 12 EARTHWORKS RELATED TO BUILDINGS
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    Part 1 General
    Part 2 Excavations
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    Part 3 Filling
    Part 4 Utility Trenches
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    Part 5 Installation of Protective Membranes


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    SECTION 13 MASONRY
    Part 1 General
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    Part 2 Mortar and Grout


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    Part 3 Accessories
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    Part 4 Unit Masonry


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    Part 5 Masonry Laying

    SECTION 14 ROOFING
    Part 1 General
    Part 2 Membrane Roofing
    Part 3 Metal and Plastic Roofing
    Part 4 Roof and Deck Insulation
    Part 5 Roofing Tiles

    SECTION 15 SECTION 15 INSULATION OF BUILDINGS


    Part 1 General
    Part 2 Building Insulation
    Part 3 Cold Stores
    QCS 2014 Contents Page 5

    SECTION 16 STRUCTURAL STEELWORKS


    Part 1 General
    Part 2 Materials
    Part 3 Drawings
    Part 4 Fabrication
    Part 5 Welding
    Part 6 Bolting
    Part 7 Accuracy of Fabrication
    Part 8 Erection
    Part 9 Accuracy of Erected Steelwork
    Part 10 Protective Treatment

    SECTION 17 METALWORK

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    Part 1 General

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    Part 2 Materials Classification
    Part 3 Metal Doors and Windows

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    Part 4 Architectural Metal Work
    Part 5 Light Metal Support and Cladding Support
    Part 6 Workmanship
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    SECTION 18 CARPENTRY, JOINERY AND IRONMONGERY
    Part 1 General
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    Part 2 Wood Treatment


    Part 3 Structural Timber (Rough Carpentry)
    se

    Part 4 Architectural Timber (Finished Carpentry, Millwork)


    Part 5 Joinery
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    Part 6 Fasteners and Adhesives


    Part 7 Ironmongery (Hardware)
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    SECTION 19 PLUMBING WORK


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    Part 1 General
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    Part 2 Water Distribution


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    Part 3 Plumbing Pipework in Trenches


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    Part 4 Cold Water Storage


    Part 5 Hot Water Storage
    Part 6 Commissioning of Systems
    Part 7 Plumbing for Gases

    SECTION 20 DRAINAGE WORKS FOR BUILDINGS


    Part 1 General
    Part 2 Internal Drainage Works
    Part 3 External Drainage Works
    Part 4 Drainage Pipes in Trenches
    Part 5 Structures Related To Drainage Work
    Part 6 Surface Water Drainage
    Part 7 Commissioning Of Systems
    QCS 2014 Contents Page 6

    SECTION 21 ELECTRICAL WORKS


    Part 1 General Provisions for Electrical Installation
    Part 2 MV Factory Built Assemblies (FBAs)
    Part 3 Protective Devices
    Part 4 Motor Starters
    Part 5 Low Voltage Variable Speed Controllers
    Part 6 Cables and Small Wiring
    Part 7 Conduits and Conduit Boxes
    Part 8 Trunking
    Part 9 Cable Trays
    Part 10 Wiring Accessories and General Power
    Part 11 Light Fittings
    Part 12 Emergency Lighting
    Part 13 Telephone Installations

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    Part 14 Structured Cabling Systems

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    Part 15 Electric Motors

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    Part 16 Power Factor Correction Capacitors
    Part 17 Standby Diesel Generator Set
    Part 18 Uninterruptible Power Supply Systems
    Part 19 Sound and Call Systems
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    Part 20 Elevators/Escalators
    Part 21 Lightning Protection
    Part 22 Earthing and Bonding
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    Part 23 Inspection and Testing


    Part 24 Documentation Format
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    Part 25 Electrical Identification


    Part 26 Electromagnetic Compatibility
    er

    Part 27 Battery and Battery Charger


    Part 28 Small Enclosures
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    Part 29 Underfloor Ducts


    Part 30 Duct Bank and Manholes
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    Part 31 Power Distribution Transformers


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    Part 32 11 kv Switchgear
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    Part 33 Actuators
    Part 34 HV Variable Frequency Drive
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    SECTION 22 AIR CONDITIONING, REFRIGERATION AND VENTILATION


    Part 1 General
    Part 2 Central Refrigeration and Air Conditioning Equipment
    Part 3 Unitary Equipment
    Part 4 Air Handling Equipment
    Part 5 Chilled Water Pipework
    Part 6 Ductwork and Air-Side Equipment
    Part 7 Thermal Insulation
    Part 8 Exhaust Fans
    Part 9 Accessories

    SECTION 23 FIRE FIGHTING AND FIRE ALARM SYSTEMS


    Part 1 General
    Part 2 Fire Alarm and Detection Systems
    QCS 2014 Contents Page 7

    Part 3 Analogue Addressable Fire Alarm Systems


    Part 4 Fire Fighting System
    Part 5 Testing and Commissioning

    SECTION 24 FINISHES TO BUILDINGS


    Part 1 General
    Part 2 Lath and Plaster
    Part 3 Dry Lining (Wall Board)
    Part 4 Special Wall Surfaces
    Part 5 Tiles
    Part 6 Terrazzo
    Part 7 Stone Flooring
    Part 8 Unit Masonry Flooring
    Part 9 Floor Screeds and Treatments

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    Part 10 Joints, Caulking and Sealants

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    Part 11 Recessed Duct Covers

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    Part 12 Carpeting
    Part 13 Other Floor Coverings
    Part 14 Ceilings
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    SECTION 25 GLASS AND GLAZING
    Part 1 General
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    Part 2 Glass
    Part 3 Workmanship
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    Part 4 Glazed Curtain Walling System


    SECTION 26 PAINTING AND DECORATING
    er

    Part 1 General
    Part 2 Surface Preparation for Painting
    ov

    Part 3 Primers, Paints and Coatings


    Part 4 Wall Coverings of Decorative Papers/Fabrics
    oit

    SECTION 27 EXTERNAL WORKS


    et

    Part 1 General
    m

    Part 2 Block Paved Areas


    Part 3 Fences and Gates
    Part 4 Fountains and Aquatic Features
    Part 5 Site Furniture
    Part 6 Flag Poles
    Part 7 Protective or Shade Cover Systems
    Part 8 Play Field and Park Equipment
    Part 9 Miscellaneous Other External Works

    SECTION 28 LANDSCAPING
    Part 1 Landscape Planting
    Part 2 Landscape Irrigation System
    Part 3 Play Equipment General Specification
    QCS 2014 Contents Page 8

    SECTION 29 RAILWAYS
    Part 1 Design Related Issues Aspects
    Part 2 Site Clearance
    Part 3 Geotechnical Specifications
    Part 4 Tunnel
    Part 5 Cut and cover Structure
    Part 6 Earthworks and Roadworks
    Part 7 Concrete Structures
    Part 8 Steel Structures
    Part 9 Drainage
    Part 10 Railway Track
    Part 11 Monitoring and Instrumentation
    Part 12 Survey and Setting Out

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    QCS 2014 Introduction Page 1

    INTRODUCTION

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

    Qatar Construction Specifications 2014 (QCS 2014) supersedes Qatar National Construction
    Standards 2010 (QCS 2010) in all respects.

    While working earnestly to benefit from new engineering developments, Laboratories and
    Standardisation Affairs in the Ministry of Environment requests that all those undertaking works

    .
    projects in the State of Qatar to implement the specifications contained herein.

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

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    QCS 2014 Document History Page 1

    DOCUMENT HISTORY

    The purpose of the Document History is to record changes to Qatar Construction Specifications. In the
    event of a revision to the technical regulation, Laboratories and Standardisation Affairs in the Ministry
    of Environment will issue the amended pages and re-issue the Document History.

    The Document History pages should contain a description of the change, the issue reference and the
    date of issue as noted below. The updated Document History should replace the superseded history
    and the revised pages of the technical regulation should be placed in the appropriate position in the
    technical regulation.

    The technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)]
    replaces Qatar Construction Specification 2002 (QCS 2002) and it supersedes in all respects.

    .
    The technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)]

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    replaces the technical regulation QS 27/2007 [Qatar National Construction Standards 2007

    .l.
    (QCS 2007)] and it supersedes in all respects.

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

    Description Issue Date


    se

    Qatar Construction Specification Original Issue April 2000


    er

    Qatar Construction Specification 2002 Revision I November 2002


    Qatar National Construction Standards 2007 Revision II July 2007
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    Qatar Construction Specifications 2010 Revision III March 2011


    Qatar Construction Specifications 2014 Revision IV October 2014
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    QCS 2014 Acknowledgements Page 1

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

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    Dr. Mohammed Saif Al-Kuwari Eng. Khalid Al-Emadi
    Assistant Undersecretary Chairman of QCS

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    Ministry of Environment Manager of Q&S Dept. Ashghal

    Technical Committee for Preparing and Development of QCS


    ta
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    as
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    Nasser Al- Naimi Abdul Hameed M. Al-Yahri Yousef Mahmoud Ahmed Nooh Meshal Saoud Al Mesallam
    er

    Deputy Chairman of QCS Sec. of the committee Asst. Sec. of the committee Ministry Of Energy & Trade
    Ministry of Environment Ministry of Environment H/ of the Documents Editing
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    Quality Supervisor -Ashghal


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    Dr. Noureddin Daas Moaaz Hashim Dr. Khaled Hassan Osman Elhussien
    Chairperson of Concrete Committee Chairperson of Road Committee Member of Concrete Committee Chairperson of Rail Committee
    Ministry of Environment Member of: Rail committee TRL Member of Road committee
    Quality Expert - Ashghal Quality Researcher - Ashghal

    Sharif Mohamed Gareth Thomas Ehab G Saleh


    Chairperson of Drainage Committee Chairperson of: Quality Committee Chairperson of: Safety Committee
    Member of Rail Sub-committee Quality Assurance & Quality Safety Specialist - Ashghal
    Design Engineer- Ashghal Control Expert - Ashghal
    QCS 2014 Acknowledgements Page 2

    Sub Committees Members

    Abdulrahim Sukik Adel M. Quraan Adrian Black Ahmed Mohd. Sayd Allan McEwan Ahmed Sami
    Concrete Committee Reviewers Safety Committee Concrete Committee Quality Committee Roads Committee
    ACES CH2M HILL MWH Ministry of Environment KBR Ashghal

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    Amr Elmotasem Arthur Hannah David Matyus David Lewis Dick Steer Dr.Hany Mohamed
    Concrete Committee Roads Committee Concrete Committee Roads Committee Drainage Committee Reviewers

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    AEB (TRL) London QPMC AMEY Ashghal Ashghal

    ta
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    Effrosyni Plexousaki Elie Khairallah Essam El Sarag Fatih Trk Fraser McCaskill Gary Cook
    as

    Quality Committee Concrete Committee Green Building Concrete&RailCommittee Quality Committee Roads Committee
    ANAS ACTS GORD Mace / EC Harris Mace / EC Harris ANAS
    se
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    Ghaleb Al Zubi Gireesh Babu Hazem Abdel Rahman Huw Woodyatt Issam A. Sarhan Jaafar. Al-Aloosi
    Reviewers Concrete Committee Roads Committee Roads Committee Website Developer Concrete Committee
    o

    ACES QDC Ashghal Exova MOE Ashghal


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    Jaafer Mohammed Jose Vellattukudy Karunarathna T A Karen OSullivan Kim Catrambone Konstantinos k
    Roads Committee Drainage Committee Drainage Committee Roads Committee Roads Committee Roads Committee
    MOE Ashghal Ashghal FUGRO Parsons Brinckerhoff Ashghal

    Martin Cahalan Mathhar Mustafa Markus Kretschmer Melina Davies Mohammed Adil Mohammed Al-Yahri
    Quality Committee Concrete Committee Concrete&RailCommittee Roads Committee Document Controller Drainage Committee
    AMEY Hilti Qatar Qatar Rail Parsons Brinckerhoff Ashghal Ashghal
    QCS 2014 Acknowledgements Page 3

    Mohamed El sherbiny Mohanasundaram Michael De Roos Michelle Magbojos Neil Courtman Neil Kirkpatrick
    Green Building Concrete Committee Safety Committee Roads Committee Quality Committee Green Building
    Ashghal QDC Ashghal Ashghal Mace Parsons Brinckerhoff

    Nicholas Ray Packiaraj Petru Ghicu Peter E. Sebaaly Peter Latham Peter Sutton
    Quality Committee Drainage Committee Drainage Committee Roads Committee Concrete Committee Safety Committee
    CH2MHill Ashgha Ashghal ANAS ReadyMix AMEY

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    Rabih Boukaidbey
    Concrete Committee
    ACTS
    Rania Hashim Abadi
    Roads Committee
    Ashghal
    Rawshan Haniffa
    Document Controller
    Ashghal ta
    Rabih Fakih
    Concrete Committee
    GREY MATTERS
    Richard James Ellis
    Roads Committee
    Gulf Laboratories
    Robert Overett
    Roads Committee
    Parsons Brinckerhoff
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    as
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    Rolando Matias Roy Cupples Salah Mousa Sheik Pahary Saleem Purayil Purayil Shyam Sundar
    er

    Quality Committee Roads Committee Safety Committee Safety Committee Document Controller Concrete Committee
    Parsons Brinckerhoff Ashghal Ministry of Labor QPM Ashghal QDC
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    Srinivasan Samiappan Subrato Mukherjee Tom Baines Yasser Berzan


    Concrete Committee Concrete Committee Safety Committee Safety Committee
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    QDC l QDC EC Harris Ashghal


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    QCS 2014 Acknowledgements Page 4

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    ORGANIZATIONAL CHART

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    Ministry of Environment

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    Dr Mohamed Saif Al-Kuwari
    Undersecretary Assistant of MoE

    Preparing and Development of Qatar Building Code Committee

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    Technical Committee for Preparing and Development of QCS

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    Eng. Khalid Al-Emadi
    Chairman of QCS

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    ov Nasser Al-Naimi
    Deputy Chairman of QCS
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    Abdul Hameed M. Al-Yahri, Yousef Mahmoud Ahmed Nooh, Gareth H. Thomas, Noureddin Daas, Moaaz Hashim, Osman Elhussien, Sharif Mohamed, Ehab Saleh

    Sub Committees
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    QUALITY CONCRETE ROADS GREEN BUILDING DRAINAGE SAFETY RAIL

    Gareth H. Thomas Noureddin Daas Moaaz Hashim Khalid Al- Emadi Sharif Mohamed Ehab Saleh Osman Elhussien
    Effrosyni Plexousaki Khaled Hassan Osman Elhussien Noureddin Daas Dick Steer Yasser Berzan Moaaz Hashim
    Neil Courtman Jaafar Isam S. Al-Aloosi Jaafer Mohammed Al Saidi Mohamed El sherbiny Mohammed Homoud Al-Yahri Peter Sutton Sharif Mohamed
    Allan McEwan Rabih Fakih Gary Cook Essam El Sarag Petru Ghicu Tom Baines Markus Kretschmer
    Martin Cahalan David Matyus Huw Woodyatt Neil Kirkpatrick Jose Vellattukudy Salah Mousa Fatih Turk
    Nicholas Ray Peter Latham Richard James Ellis Packiaraj Thangaswamy Michael De Roos
    Rolando Matias Gireesh Babu.K.M Arthur Hannah Karunarathna T A. Kithsiri Adrian Black
    Fraser McCaskill Srinivasan Samiappan Khaled Hassan Sheik Pahary
    Shyam Sundar Rajaram Michelle Magbojos
    Mohanasundaram Rangasamy
    Ahmed Mohamed El Sayd
    Amr Elmotasem Elkady Contributors to
    Road Lighting Work Group Website Developer Reviewers Document Controllers
    Abdulrahim Mohammed Road Section
    Mathhar Ghazi Mustafa
    Sabet Hajem Ibrahi Peter E. Sebaaly Kim Catrambone Issam A. Sarhan
    Dr.Hany Mohamed Yousef Mahmoud Nooh
    Elie Khairallah Karen OSullivan Melina Davies Ghaleb Al Zubi Saleem Puthiya Purayil
    Subrato Mukherjee Konstantinos Kanellaidis Hazem Abdel Rahman Adel M. Quraan Mohammed Adil
    Rabih Bahij Boukaidbey David Lewis Rawshan Haniffa
    Fatih Trk Recycling Roy Cupples
    Rania Hashim Al-Abadi
    Robert Overett
    Moaaz Hashim
    Osman Elhussien
    Gary Cook
    Ahmed Sami Sayed Abbas
    QCS 2014 Feedback Page 1

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

    By post: The Coordinator


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

    By e-mail: qcs@moe.gov.qa

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

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    Section number and title
    Part number and title

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    Clause and paragraph number
    Page
    Your name and contact details
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    Please use the following feedback form where possible and applicable.

    QCS 2014 Feedback


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    Section name and title


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    Part name and title


    Clause and paragraph number
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    Page
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    Name and contact details


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    Date
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    Comments / Suggestions / Technical Justifications


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    QCS 2014 Section 01: General Page1
    Part 01: Introduction

    1 INTRODUCTION ........................................................................................... 2

    1.1 GENERAL ...................................................................................................... 2


    1.1.1 Scope of this Section 2
    1.1.2 Scope of the Qatar Construction Specification 2
    1.1.3 References 2
    1.1.4 Precedence of Specification and Documents 2
    1.2 COMPLIANCE ............................................................................................... 3
    1.2.1 Compliance with the Qatar Construction Specification 3
    1.2.2 Compliance with the General Conditions of Contract 3
    1.3 STANDARDS ................................................................................................. 3

    .
    1.3.1 References to Standards 3

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    1.3.2 Government Published Specifications, Regulations, Notices and Circulars 3
    1.3.3 Survey Marks 5

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    1.4 TERMS AND DEFINITIONS .......................................................................... 5
    1.4.1
    1.4.2
    General
    Approved ta 5
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    1.4.3 Contract 5
    1.4.4 Contract Documents 5
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    1.4.5 Contractor 5
    1.4.6 Drawings 6
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    1.4.7 Engineer 6
    1.4.8 Engineers Representative 6
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    1.4.9 Government 6
    1.4.10 Government Departments and Utility Services 6
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    1.4.11 Guarantee 6
    1.4.12 Independent Agency 6
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    1.4.13 Owner 6
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    1.4.14 Permanent Works 6


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    1.4.15 Plant 7
    1.4.16 Project Documentation 7
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    1.4.17 Singular and Plural 7


    1.4.18 Site 7
    1.4.19 Specifications 7
    1.4.20 Specified 7
    1.4.21 Temporary Works 7
    1.4.22 Works 7
    1.5 ABBREVIATIONS AND SYMBOLS ............................................................... 7
    1.5.1 General 7
    1.5.2 Site Conditions 9
    1.6 LANGUAGE ................................................................................................. 10
    1.6.1 Contract Language 10
    QCS 2014 Section 01: General Page2
    Part 01: Introduction

    1 INTRODUCTION
    1.1 GENERAL

    1.1.1 Scope of this Section

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

    1.1.2 Scope of the Qatar Construction Specification

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

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

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    1.1.3 References

    1 The following standards are referred to in this Part:


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    BS 6100......................Building and civil engineering: Vocabulary
    BS ISO 80000 ............Quantities and Units
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    BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions


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

    buildings
    ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures
    er
    ov

    Guide to the Design of Concrete Structures in the Arabian Peninsula, 2008


    Seismic hazard and seismic design requirements for the Arabian Peninsula region. The 14th
    o

    World Conference on Earthquake Engineering October 2008


    it

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

    Civil Aviation & Meterology.


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    1.1.4 Precedence of Specification and Documents

    1 The precedence of documents shall be:

    (a) Particular Conditions of Contract.


    (b) General Conditions of Contract.
    (c) Project Specific Specification.
    (d) Project Specific and General Drawings.
    (e) Qatar Construction Specification.
    QCS 2014 Section 01: General Page3
    Part 01: Introduction

    1.2 COMPLIANCE

    1.2.1 Compliance with the Qatar Construction Specification

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

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

    1.2.2 Compliance with the General Conditions of Contract

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

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

    ta
    qa
    1.3 STANDARDS

    1.3.1 References to Standards


    as

    1 Any standard referred to in this Specification shall be deemed to be the version and/or
    se

    standard(s), that was current forty-two days prior to the date of return of Tenders.
    er

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


    Specification.
    ov

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

    necessary.
    it
    et

    1.3.2 Government Published Specifications, Regulations, Notices and Circulars


    m

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

    (a) The General Conditions of Contract.


    (b) The Qatar Construction Specification (QCS) issued by the Qatar Standards,
    Laboratories and Standardisation Affairs, Ministry of Environment, 2014 and all
    revisions and addenda issued by the same ministry prior to the date of the
    announcement inviting tenderer.
    (c) The Code of Practice and Specification for Road Openings in the Highway prepared by
    the Ministry of Industry & Public Works, January 1992.
    (d) The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of
    Public Works.
    (e) The Qatar Survey Manual prepared by the Survey Section of the former Ministry of
    Industry & Public Works.
    QCS 2014 Section 01: General Page4
    Part 01: Introduction

    (f) The Qatar Traffic Manual prepared by the former Ministry of Public Works and the
    Qatar Highway Design Manual prepared by MMAA, 1997.
    (g) The Traffic Control at Road Works Manual issued by the former Ministry of Industry &
    Public Works.
    (h) Rules, Regulations and Code of Practice for Design and Installation of Air
    Conditioning, Heating, Ventilation & Refrigeration (ACHVR) Systems for Government
    Buildings, 2nd Edition, 1989, prepared by Qatar General Electricity and Water
    Corporation (QGEWC).
    (i) Regulations for the Installation of Electrical Wiring by the former Qatar National
    Telephone Services.
    (j) The Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air
    Conditioning Equipment, Feb 2006 Edition prepared by the Qatar General Electricity
    and Water Corporation (QGEWC).

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

    rw
    (l) Any current and relevant regulations, notices or circulars issued by the Public Works
    Authority, Ministry of Municipal Affairs & Agriculture (including the previous Ministry of

    ta
    Public Works and the previous Ministry of Industry and Public Works), Qatar General
    qa
    Electricity and Water Corporation (QGEWC) (including the previous Ministry of
    Electricity and Water), Qatar Telecom (Q-TEL), the Qatar Standards, the Supreme
    Council for the Environment and Natural Reserves or the appropriate local Municipality
    as

    prior to the date of the announcement inviting tenderer.


    (m) State of Qatar Law No. 30 of 2002 and all subsequent amendments concerning The
    se

    Environment and Natural Resources Protection Articles 6, 17, 19 & 35.


    er

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

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

    (p) Standard Method of Measurement of Building Works published by the Ministry of


    it

    Public Works, Engineering Services Department, 1973.


    et

    (q) Safety Rules issued by the Electricity Networks Department of the former Ministry of
    m

    Electricity and Water.


    (r) The Jointing Manual prepared by the Electricity Networks Department of the former
    Ministry of Electricity and Water.
    (s) The Labour Law, No. (14) of The Year 2004 Published by Labour Department of
    Ministry of Civil Service Affairs & Housing, 2005.
    (t) Developers Drainage Guide prepared by the Public Works Authority, 2007.
    (u) Qatar Traffic Law No. 19 of the Year 2007.
    (v) CDD (Civil Defence Department) Fire Safety Handbook.
    (w) Civil Defence Law No. 9 of the Year 2012.
    (x) Worker Rights Booklet 2009 (National Human Rights Committee).

    2 The Contractor shall be deemed to have his own copy of the Government specifications,
    regulations, notices and circulars given at (a) to (t) above.
    QCS 2014 Section 01: General Page5
    Part 01: Introduction

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

    1.3.3 Survey Marks

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

    2 The Contractor shall be responsible for the protection of the survey marks within the
    boundaries of the site for the duration of the contract period, and shall be liable for all costs of

    l .
    any remedial work required by the Engineer.

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

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

    which may become due to the Contractor.


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    1.4 TERMS AND DEFINITIONS


    er

    1.4.1 General
    ov

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

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

    1.4.2 Approved

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

    1.4.3 Contract

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

    1.4.4 Contract Documents

    1 means documents which together form the Contract

    1.4.5 Contractor

    1 means the party responsible for the construction of the Works.


    QCS 2014 Section 01: General Page6
    Part 01: Introduction

    1.4.6 Drawings

    1 The drawings included in the Project Documentation.

    1.4.7 Engineer

    1 means the party appointed by the Owner to administer the Contract

    1.4.8 Engineers Representative

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

    1.4.9 Government

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

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    1.4.10 Government Departments and Utility Services

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

    1.4.11 Guarantee
    se

    1 A Guarantee is a written assurance that a material, product, component, item of equipment,


    finishing or any other part of the Works meets certain defined standards or quality criteria
    er

    and/or lasts for a certain length of time.


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


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    1.4.12 Independent Agency


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    et

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

    Contract Documents

    1.4.13 Owner

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

    1.4.14 Permanent Works

    1 means the permanent works, forming part of the Works, to be designed and / or executed
    and completed by the Contractor under the Contract.
    QCS 2014 Section 01: General Page7
    Part 01: Introduction

    1.4.15 Plant

    1 means, irrespective of ownership, all plant, facilities, temporary structures and


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

    1.4.16 Project Documentation

    1 All documents associated with and applicable to the Project Contract.

    1.4.17 Singular and Plural

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

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    requires.

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    rw
    1.4.18 Site

    1 Means the places provided by the Owner where the permanent works are to be executed and

    ta
    to which Plant and Materials are to be delivered, any other places that may be specified in the
    Contract Documents or by an instruction of the Engineer as forming part of the Site
    qa
    1.4.19 Specifications
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    1 All specifications contained in the Contract including any modifications or additions thereto as
    se

    may from time to time be issued or approved in writing by the Engineer.

    1.4.20 Specified
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    1 Specified in the Project Documentation.

    1.4.21 Temporary Works


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    1 means temporary works of every kind (other than Plant) required on the Site for the execution
    et

    and completion of the Permanent Works and the remedying of Defects.


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    1.4.22 Works

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

    1.5 ABBREVIATIONS AND SYMBOLS

    1.5.1 General

    1 Units shall generally be in accordance with the Systm International dUnits and the relevant
    provisions of BS ISO 80000
    QCS 2014 Section 01: General Page8
    Part 01: Introduction

    2 The following abbreviations are used in this Specification:


    microns
    A ampere
    C Celsius
    c centi
    d day
    dia diameter
    g gram (me)
    h hour
    ha hectare
    J joule
    k kilo
    l litre
    M mega

    .
    m metre

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    .l.
    m milli

    rw
    N Newton
    No. number
    nr number
    Pa
    r
    Pascal
    radius ta
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    sec second
    t tonne
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    V volt
    W Watt
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    3 Reference to a technical society, institution, association or governmental authority is made in


    the Specifications in accordance with the following abbreviations:
    er

    AASHTO American Association of State Highway and Transportation Officials


    ov

    ACI American Concrete Institute


    ANSI American National Standards Institute
    ASME American Society of Mechanical Engineers
    o

    ASTM American Society for Testing & Materials


    it

    AWS American Welding Society


    et

    AWWA American Water Works Association


    BS British Standard
    m

    BSI British Standard Institution


    C & CA Cement and Concrete Association
    CEE Commission of approval of Electrical Equipment
    CIBSE Chartered Institution of Building Services Engineers
    CIRIA Concrete Industry Research and Information Association
    CRSI Concrete Reinforcing Steel Institute
    CS Concrete Society
    DIN Deutsches Institute fur Normung (German Institute for Standardization)
    EIA Electronic Industries Association
    EN European Standards (Euro-Norm)
    FHWA Federal Highway Authority
    FM Factory Mutual Engineering Division
    GS Gulf Standards
    ICE Institution of Civil Engineers
    IEC International Electrotechnical Commission
    IEE Institution of Electrical Engineers
    QCS 2014 Section 01: General Page9
    Part 01: Introduction

    IEEE Institute of Electrical and Electronic Engineering


    ISO International Organization for Standardization
    LPC Loss Prevention Council
    LPCB Loss Prevention Certification Board
    MMAA Ministry of Municipal Affairs and Agriculture
    NEMA National Electrical Manufacturers Association
    NFPA National Fire Protection Agency
    PCI Prestressed Concrete Institute
    PWA Public Works Authority (Ashghal)
    QCS Qatar Construction Specification
    QGEWC Qatar General Electricity & Water Corporation
    QS Qatar Standards (Laboratories and Standardisation Affairs, Ministry of
    Environment)
    Ooredoo Qatar Telecom Provider

    .
    SIS Swedish Standards Institute

    l
    .l.
    UK DOT United Kingdom Department of Transport
    UPDA Urban Planning and Development Authority

    rw
    VDE Verband Deutscher Elektrotechniker (Association for Electrical, Electronic
    and Information Technologies)

    1.5.2 Site Conditions


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

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


    Minimum ambient temperature ........................... 5C
    se

    Design ambient temperature ............................... 50C


    er

    Maximum metal temperature under the sun ....... 85C


    Maximum ambient humidity ................................ 100%
    ov

    Minimum ambient humidity ................................. 20%


    Design ambient humidity ..................................... 100%
    it o

    50-year return period Wind Speed:


    et

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

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


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

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

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

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

    5 Under certain climatic conditions, considerable condensation may take place.

    6 A considerable amount of salt is contained in the atmosphere which together with the
    relatively high ambient humidity, can produce sever corrosion problems.
    QCS 2014 Section 01: General Page10
    Part 01: Introduction

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

    8 The prevailing wind directions are from the north and west.

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

    Peak Ground Acceleration 0.2 second Spectral 1 second Spectral


    (PGA) Acceleration (g) - Ss Acceleration (g) S1

    475 year 2475 year 475 year 2475 year 475 year 2475 year

    .
    0.045 0.10 0.090 0.147 0.045 0.065

    l
    .l.
    10 Wind tunnel test is recommended for buildings under below criteria

    rw
    (a) Total building height exceeding 120m from ground.
    (b) Structure with irregular geometry or shape.
    ta
    qa
    (c) Unusual terrain or surrounding structure in the area.
    (d) Any other factor as per design requirements or designer recommendation.
    as

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

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


    er

    12 Building structure design working life shall be minimum as specified below


    ov

    Design working Indicative design Examples


    life category working life (years)
    o

    1 10 Temporary structures (a)


    it
    et

    2 10 to 25 Replaceable structural parts, eg. Gantry girders, bearings


    m

    3 15 to 30 Storage and similar structures

    4 50 to 75 Building structures and other common structures

    5 120 Civil engineering structures like bridges, tunnel etc.

    (a) Structures or parts of structures that can be dismantled with intention of being reused, arent temporary
    structures.

    1.6 LANGUAGE

    1.6.1 Contract Language

    1 All communications, meetings and documentation shall be in English.

    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 10: Occupational Health and Safety

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

    10.1 GENERAL ...................................................................................................... 3


    10.1.1 Scope 3
    10.1.2 Responsibility 3
    10.1.3 Organisation for Occupational Health and Safety 4
    10.1.4 Reporting Accidents 5
    10.1.5 General Sanitation 6
    10.1.6 Safety Notice Board 6
    10.1.7 Compensation for Damage 7
    10.1.8 Occupational Health and Safety Performance 7
    10.1.9 Occupational Health and Safety Leadership and Accountability 7
    10.1.10 Safe-working Arrangements 8

    l .
    10.1.11 Labour Rights, Benefits & Obligations 8

    .l.
    10.1.12 Language barriers and communications issues 10

    rw
    10.1.13 Communications, Consultations and Participation 10
    10.1.14 Management Review 11
    10.2
    ta
    CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN ............. 11
    qa
    10.2.1 General 11
    10.2.2 Occupational Health and Safety Policy 16
    10.2.3 Risk Assessment and Job Hazard Analysis 16
    as

    10.2.4 Intervention 16
    10.2.5 Requirement for Training 17
    se

    10.2.6 Method Statements 19


    er

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


    10.3.1 General 19
    ov

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


    o

    10.4.1 Background 20
    it

    10.4.2 Requirements 21
    et

    10.4.3 Phase One: Gap Analysis (as is) 21


    10.4.4 Phase Two: Implementation (to be) 22
    m

    10.4.5 Phase Three: Future Requirements 22


    10.4.6 What Should We Do During An Earth Quake? 23
    10.4.7 What Should We Do After An Earth Quake? 23
    10.5 SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS ..................... 24
    10.5.1 Permits 24
    10.5.2 Guarantee 24
    10.5.3 Mechanical Plant, Machinery and Equipment 24
    10.5.4 Existing Utilities 25
    10.5.5 Excavations 26
    10.5.6 Warning Signs 28
    10.5.7 Confined Spaces 28
    10.5.8 Lifting Operation 30
    10.5.9 Lifting Gear 30
    10.5.10 Scaffolding 31
    QCS 2014 Section 01: General Page 2
    Part 10: Occupational Health and Safety

    10.5.11 Hot work and Welding 32


    10.5.12 Compressed Gas Cylinders 33
    10.5.13 Working at Height 34
    10.5.14 Electrical 36
    10.6 FIRST AID ................................................................................................... 37
    10.6.1 First Aid and Clinic 37
    10.7 FIRE PRECAUTION AND PREVENTION ................................................... 37
    10.7.1 General 37
    10.7.2 Emergency Equipment 39
    10.7.3 Hazardous Substances 40
    10.8 SAFETY OF THE PUBLIC ........................................................................... 41

    .
    10.8.1 Working in Public Areas 41

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

    rw
    10.9.1 General 42
    10.9.2 Personal Protective Equipment (PPE) / Attire 42
    10.9.3
    10.9.4
    Safety Equipment
    Support Facilities for Contractors Staff and Labour ta 42
    43
    qa
    10.9.5 Summer Working Conditions and fatigue 45
    10.9.6 Additional Environmental Protection and Pollution Control 45
    as

    10.9.7 Plant and Equipment Test Certificates 46


    10.10 LABOUR ACCOMODATION ....................................................................... 46
    se

    10.10.1 General 46
    er

    10.10.2 Quality of Labour Accommodation 46


    10.10.3 Provision for Fire Safety 47
    ov

    10.10.4 Provision for Health Care 47


    10.10.5 Access to Transport 48
    o

    10.10.6 Access to Religious, Social and Domestic Facilities 48


    it

    10.10.7 Access to Communications 49


    et

    10.10.8 Number, Quality and Location of Sanitation Facilities 49


    10.10.9 Food Preparation Areas 49
    m

    10.10.10 Pest and Vermin Control 50


    10.10.11 Security at Labour Accommodation 50
    10.10.12 Social Issues 50
    10.10.13 Competence of Labour Accommodation Management 51
    10.10.14 Environmental Conditions at Labour Accommodation 51
    10.10.15 Health and Safety for Labour Accommodation Residents 52
    QCS 2014 Section 01: General Page 3
    Part 10: Occupational Health and Safety

    10 OCCUPATIONAL HEALTH AND SAFETY


    10.1 GENERAL

    10.1.1 Scope

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

    2 Related Sections and Parts are as follows.


    This Section Part 4 Protection
    Part 8 Building Demolition
    Part 9 Materials

    .
    Part 11 Engineers Site Facilities

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    Part 13 Setting-out of the Works

    rw
    Section 11 Health and Safety
    10.1.2 Responsibility

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

    (a) Safe plant and equipment;


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    (b) Safe means of handling, transporting and storage of articles and substances;
    (c) Adequate training, instruction, information and supervision;
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    (d) A safe place of work with safe access to and egress from the place of work;
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    (e) A safe and healthy environment; and


    (f) Adequate welfare facilities.
    it o

    2 It is the Contractors responsibility to conduct his operations in such a manner as to prevent


    et

    injury to persons or damage to property. The Contractor shall take precautions for protection
    against risks and shall inspect Occupational Health and Safety conditions where the Works
    m

    are being executed.

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

    4 The Contractor shall note that Occupational Health and Safety (OHS) shall be treated with
    high importance at all stages of the Contract. Contractor shall understand that the Contract
    Price includes the Execution Programme for provision and implementation of an
    Occupational Health and Safety Policy and Plan to ensure the highest standards are
    enforced throughout Construction, Pre-commissioning and Commissioning.
    QCS 2014 Section 01: General Page 4
    Part 10: Occupational Health and Safety

    5 The Contractors attention is drawn to the requirements of latest revision of:

    (a) Qatar Construction Specification QCS,


    (b) Qatar Law No.14 of the Year 2004 The Labour Law, and the ministerial decisions
    issued in implementation of the provisions of the Labour Law issued by Law No. 14 of
    2004,
    (c) Qatar Traffic Law No. 19 of the Year 2007,
    (d) Environmental Protection Law No. 30 of the Year 2002 and Decision No. (4) for the
    year 2005 by issuing the executive regulations of Environmental Protection Law,
    (e) Civil Defence Law No. 9 of the Year 2012,
    (f) CDD (Department of Civil Defence) Fire Safety Handbook; and
    (g) Worker Rights Booklet 2009 (National Human Rights Committee).

    l .
    The Contractor is required to fully comply with the stated requirements relating to

    .l.
    Occupational Health and Safety. In the event that legislation is updated the latest version

    rw
    shall be followed.

    6 The Contractor shall ensure that Contractor Personnel and Subcontractors employees

    ta
    comply with all requirements of latest revision of QATAR legislation mention above (but not
    limited to). Compliance with the standards shall be considered as a minimum requirement
    qa
    and Contractor shall establish additional arrangements as circumstances may require. Any
    failure by Contractor to obtain copies of that mentioned laws applicable to the Contract shall
    as

    in no way relieve the Contractor from any responsibilities or obligation under the Contract.

    The Contractors Representative shall be responsible for all Occupational Health and Safety
    se

    7
    matters during the performance of the Work up to and including the Completion Date. The
    Contractors Representative shall ensure that an effective Occupational Health and Safety
    er

    management organization is maintained at all times to undertake the duties to comply with
    ov

    this requirement.

    10.1.3 Organisation for Occupational Health and Safety


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    1 The Contractor shall submit an Occupational Health and Safety Organisation Plan detailing
    et

    planning and management considerations for construction at an organisational level for the
    Engineers approval within Thirty (30) days of the award of the Contract.
    m

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

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

    (a) The details of its proposed competent and experienced Occupational Health and
    Safety Manager. The minimum education for the proposed Occupational Health and
    Safety Manager are but not limited to Bachelor degree in Engineering / Science or
    equivalent with 10 years experiences in the same field as Safety Manager and the
    ability to communicate with all nationalities, plus Professional OHS Qualification by
    Examination (NEBOSH, IOSH Managing Safely, OSHA 30 hours, ... etc), Management
    Qualification prefer certified as BS OHSAS 18001 lead auditor, implementation and
    continues improvement Relevant Training Attendance. The Engineer shall review the
    details and if necessary interview the proposed individual to assess his/her suitability
    for the position prior to giving approval for appointment. The Contractor is not
    QCS 2014 Section 01: General Page 5
    Part 10: Occupational Health and Safety

    permitted to execute any form of Work on the Worksite until such time as an approved
    Occupational Health and Safety Manager has been deployed on a full time basis to the
    Worksite. The Contractor shall not remove the appointed Occupational Health and
    Safety Manager without prior approval from the Engineer.
    (b) Deputy Occupational Health and Safety Manager who is capable of performing all of
    the duties of the Occupational Health and Safety Manager in the event of his absence.
    The requirements and procedure outlined in Clause (a) above applies equally to the
    appointment of the Deputy Occupational Health and Safety Manager.

    4 The Contractor shall appoint Occupational Health and Safety Officers and support staff in
    sufficient numbers to ensure the effective function of the Occupational Health and Safety
    discipline within the Contractors organisation. The minimum education for the Occupational
    Health and Safety Officer are HND / HNC with 4 years experiences in the same field as
    Safety officer, certified from NEBOSH, IOSH or OSHA 30 hours, Professional in control and

    .
    monitoring the site activity. The Contractor shall appoint and deploy full time on the Worksite

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    .l.
    one Occupational Health and Safety Officer for each and every 50 persons employed at the
    Worksite. For a less than 50 persons employed at the Worksite, a minimum of one (1) Safety

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    Officer shall be present on site during all working hours each day throughout the Contract
    period. This is in addition to the Occupational Health and Safety Manager and his Deputy.

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

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


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    10.1.4 Reporting Accidents


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

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

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

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

    5 The Contractor shall produce and submit to the Engineer monthly performance reports and
    incident reports. Reports shall be in the format approved by the Engineer.
    QCS 2014 Section 01: General Page 6
    Part 10: Occupational Health and Safety

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

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

    (a) Submit incident notifications immediately;


    (b) Conduct the investigation;
    (c) Prepare the report with conclusions and recommendations;
    (d) Prepare appropriate plan of corrective action;
    (e) Include in monthly Health and Safety statistics report;

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

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    10.1.5 General Sanitation

    1 The Contractor shall maintain the Site and all working areas in a sanitary condition and in all

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    matters of health and sanitation shall comply with the requirements of the Supreme Council
    of Health and the Public Works Authority.
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    2 The Contractor is responsible for all measures necessary to prevent the breeding of
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    mosquitoes on the Site for the duration of the Contract.

    3 The Contractor shall ensure that pests are not permitted to the Site facility by initiating a
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    routine pest control program. Non-toxic pest control methods shall be used.
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    4 The disposal surplus water and the accompanying growth of trees and the proliferation of
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    insects and rodents. Does the site cause an environmentally danger to the surrounding area?

    10.1.6 Safety Notice Board


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

    2 The notice boards shall be in Arabic, English and;

    (a) In all other languages which are the mother tongue of five or more of the Contractors
    employees, or
    (b) The preferred languages (can be understood) by the workers on the Worksite.

    3 The Contractors employees shall be made fully aware of the notice boards prior to
    commencing duties on Site.

    4 The Contractor shall maintain up to date copies of all industry codes and standards that apply
    to the Work.
    QCS 2014 Section 01: General Page 7
    Part 10: Occupational Health and Safety

    10.1.7 Compensation for Damage

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

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

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

    10.1.8 Occupational Health and Safety Performance

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    1 The Contractor shall ensure acceptable Occupational Health and Safety performance of all

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    Subcontractors, visitors, vendors, public and other parties that may enter the Worksite or the

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    amounts identified in the Bills of Quantities.

    2 Should acceptable Occupational Health and Safety performance not be maintained by the

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    Contractor then the Engineer may, in addition to any other amounts withheld under the
    Contract, withhold up to 10% of the amount of any interim invoice issued by the Contractor.
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    3 The Contractor shall develop and implement programmes which shall act as incentives for
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    their teams at all levels, to make a positive contribution to good health and safety
    performance.
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    10.1.9 Occupational Health and Safety Leadership and Accountability


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    1 The Contractor shall be committed to Health and Safety leadership and this is to be achieved
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    through working in partnership with the main project stakeholders including the Engineer and
    the Client.
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    2 The Contractor shall demonstrate commitment to the safety, health and welfare of all
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    stakeholders and workers on projects and shall demonstrate leadership in achieving the
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    following objectives:
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    (a) A safe, healthy workplace


    (b) Be consulted on their working conditions, to be heard, and to influence their working
    conditions
    (c) Return home from work unharmed at the end of each working day; to which everyone
    has a right to.

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

    4 The Contractors senior management shall visibly demonstrate support, commitment,


    Leadership and Accountability on all health and safety issues by the following actions:

    (a) The Engineers Zero Harm Initiative;


    QCS 2014 Section 01: General Page 8
    Part 10: Occupational Health and Safety

    (b) Training employees to work safely;


    (c) Recognizing and rewarding employees;
    (d) Identify risks to health and safety and develop mitigation/control plans and
    communicate these to workers;
    (e) Reinforce safe work practices;
    (f) Place health and safety as the first item on the agenda at meetings.
    (g) Allocate adequate resources for health and safety management and implementation
    (h) Develop health and safety targets and objectives and measure and review
    performance;
    (i) Foster positive health and safety culture and behaviour through their own actions;
    (j) Treat health and safety as a core value equal in importance with productivity, quality

    l .
    and ethical standards;

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    (k) Participate in health and safety meetings and safety walkabouts;

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    (l) Develop efficient contingency plans and allocate adequate emergency resources;
    (m)
    (n)
    Provide trained and competent workforce;
    Promote personal health and well-being; and ta
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    (o) Seek to exceed current legislation in relation to welfare and labour facilities.
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    10.1.10 Safe-working Arrangements


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


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    2 Contractor to have safe-working arrangement that ensures:


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    (a) That health and safety concerns can be raised and associated actions taken
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    (b) Employees can stop work immediately where they believe they or others are at risk of
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    harm
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    (c) No disciplinary action is taken against those who use the worksafe arrangement to
    raise a genuine health and safety concern
    (d) That the process is cascaded to their subcontractors

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

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

    10.1.11 Labour Rights, Benefits & Obligations

    1 The Contractor shall document implementation of Labour Law, in particular with respect to
    the following:
    QCS 2014 Section 01: General Page 9
    Part 10: Occupational Health and Safety

    (a) Recruitment The Contractor shall maintain an up-to-date list of all agents/agencies
    used and should provide copies of licences for same to the Engineer. The Contractor
    shall, through their best endeavours, satisfy themselves, and the Engineer, that
    recruitment agents/agencies used do not charge recruits any fees inconsistent with
    those allowed for under the Labour Law (Qatar Law no.14 of the year 2004).
    (b) Contracts The Contractor shall retain, for inspection by the Engineer, copies of
    written employment contracts for all employees working on the project. Such
    employment contracts shall be in accordance with the requirements of the Labour Law
    and no contract clause may contravene the Labour Law.
    (c) Wages A Wage Register shall be retained in accordance with the requirements of
    the Labour Law. The Contractor shall update the Wage Register to ensure that
    employee wages, including relevant overtime payments, are paid in a timely fashion
    and in a manner consistent with the requirements of the Labour Law. These records
    shall be available for inspection by the Engineer and shall clearly identify overtime

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    payments and rates.

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    (d) Severance Pay The Contractor shall retain records to demonstrate that payment of

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    severance payments have been made, where appropriate, in accordance with Article
    132 of the Labour Law.
    (e)
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    Records & Files These shall be retained in accordance with the Labour Law, and
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    shall be made available to the Engineer for inspection.
    (f) Work Rules & Disciplinary Rules These shall be in accordance with the Labour Law,
    shall be conspicuously displayed, and shall be provided to the Engineer.
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    (g) Working Hours & Leave - The Contractor shall retain records to demonstrate that all
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    employees working hours and leave allowances are consistent with the requirements
    of the Labour Law.
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    (h) Collective Labour Disputes - Any/all collective labour disputes shall be dealt with in
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    accordance with the requirements of the Labour Law. Complete records of all such
    disputes shall be retained by the Contractor for review by the Engineer. As a
    minimum, the Contractor shall inform the Engineer immediately, on receipt of
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    complaint/claim from the employees.


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    (i) Subcontracts As such, obligations, relating to Recruitment, Contracts, Wages,


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    Records & Files, Work Rules & Disciplinary Rules, Working Hours & Leave and
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    Collective Labour Disputes shall be passed on to the subcontractor in the event that
    works are subcontracted by the Contractor. Similarly, subcontractor records shall be
    made available to the Engineer.

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

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

    4 The Contractor shall facilitate contact between project employees and relevant independent
    bodies such consulates, NGOs, or other relevant organisations offering social support. A list
    of such local contacts shall be provided to new employees during their induction process.
    An up-to-date list of contact details for these organisations shall also be displayed in public
    areas such as the canteen, recreational areas, etc.
    QCS 2014 Section 01: General Page 10
    Part 10: Occupational Health and Safety

    10.1.12 Language barriers and communications issues

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

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

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

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

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    understand
    (c) Appropriate arrangements are made to ensure that instructions are effectively

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    communicated to and understood by all team members
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    (d) Particular attention has been given to the communication requirements of safety
    critical workers. ensuring a translator is available who is capable of instructing the non-
    English speaking personnel in safety and other operational matters, and
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    (e) Maintaining a reasonable ratio of non-English speaking personnel to each translator at


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


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    10.1.13 Communications, Consultations and Participation


    it
    et

    1 The Contractor shall be required to disseminate and transfer information regarding Health
    and Safety issues. Typical information to be communicated should include but not be limited
    m

    to; any new policies or procedures and general awareness.

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

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

    (a) Meetings; Health and safety meetings shall be conducted on a weekly basis separate
    from other meeting that have safety on the agenda
    (b) Safety Alerts; Safety alerts shall be produced by the Contractor after a Major
    Accident/Incident or when appropriate.
    (c) Notice Boards; Information that shall be included as a minimum on an office notice
    board is any relevant emergency procedures, policy statement, safety alerts or updates
    QCS 2014 Section 01: General Page 11
    Part 10: Occupational Health and Safety

    (d) Campaigns; Health and safety campaigns must be initiated by the Contractor to
    implement throughout the year. At least 4 campaigns must be run annually on a pro-
    rata basis. One of the campaigns must detail heat stress before the summer months.
    (e) Posters/Signs; Must be focused on themes relevant to site specific work
    activities/hazards
    (f) Safety Awards; The Contractor shall initiate a scheme whereby he recognises and
    rewards for positive health and safety related performance by individuals. This shall be
    on a monthly basis and communicated throughout the project workforce.

    10.1.14 Management Review

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

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

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    changes to:
    (a) Health and safety policy;
    (b)
    (c)
    Objectives and targets;
    Action plans; ta
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    (d) Follow-up action from previous meetings;
    (e) Health and safety system suitability;
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    (f) Audit results;


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    (g) Preventive and corrective actions;


    (h) Regulatory changes;
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    (i) Continual improvement measures;


    (j) Performance measures;
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    (k) Major procedure and risk review changes; and


    (l) Health and safety plans.
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    10.2 CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN


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    10.2.1 General

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

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

    3 The Safety Plan shall include the Contractors proposals for accident prevention. Accident
    prevention shall include but not be limited to training, monitoring and review of safety related
    procedures, enforcement of safety related matters and promoting safety awareness.
    QCS 2014 Section 01: General Page 12
    Part 10: Occupational Health and Safety

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

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

    6 The Safety Plan shall be specific to one Contract.

    7 The Contractor shall regularly review the suitability of the Safety Plan. The Contractor shall

    l .
    undertake a full formal review of the Safety Plan annually on the date of award of the

    .l.
    Contract or when necessary but no less than 6 monthly intervals and submit the findings of

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    the review to the Engineer within 14 days of that date along with an amended plan should any
    amendment be required.

    8
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    The Safety Plan shall contain the Contractors Occupational Health and Safety Policy. (refer
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    to 10.2.2)

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

    10 The Safety Plan shall include the contract risk assessment and detail the arrangements for
    o

    ensuring that it is updated to reflect any changes throughout the duration of the Work.
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    11 The Safety Plan shall detail the arrangements for undertaking job hazard analysis and
    ensuring that such analysis is included in each and every method statement.
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    12 The Safety Plan shall detail the management arrangements and standards to be used for
    each of the following:

    (a) Scaffolding
    (b) Suspended Working Platforms
    (c) Fall Prevention and Fall Arrest
    (d) Prevention of Falling Objects
    (e) Excavations
    (f) Electricity
    (g) Structural Steel Erection
    (h) Demolition and Dismantling
    QCS 2014 Section 01: General Page 13
    Part 10: Occupational Health and Safety

    (i) False work and Formwork


    (j) Reinforcement and Concreting
    (k) Cladding and Roof work
    (l) Confined Spaces
    (m) Lifting Appliances and Lifting Gear
    (n) Mobile Plant and Vehicles
    (o) Mobile Elevating Working Platforms
    (p) Construction Lifts
    (q) Machinery and Equipment
    (r) Power Tools

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    (s) Hazardous Substances

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    (t) Hot Work and Welding

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    (u) Fire Prevention and Protection
    (v) Access and Egress
    (w) Housekeeping ta
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    (x) Warning Signs and Barricades
    (y) Material Handling, Transportation and Storage
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    (z) Lock Out and Tag Out


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    (aa) Temporary Works


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    (bb) Temporary Facilities


    (cc) Underground and Overhead Utilities
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    (dd) Working Over or Adjacent to Water


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    (ee) Working Environment


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    (ff) Personal Protective Equipment


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    (gg) Site Traffic Control (including setting and taking down of all temporary traffic devices)
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    13 The Safety Plan shall detail the arrangements that the Contractor shall use to ensure
    acceptable Occupational Health and Safety performance of all Subcontractors that may enter
    the Worksite. It shall detail the arrangements for evaluating Subcontractors prior to them
    being contracted to undertake Work. It shall detail the methods that the Contractor shall use
    to monitor their work and the penalties that shall be imposed should acceptable standards
    not be maintained.

    14 The Safety Plan shall detail the manner in which the Contractor shall review, approve and
    incorporate all Subcontractor Occupational Health and Safety plans, risk assessments and
    method statements and incorporate them into their Occupational Health and Safety
    management system.
    QCS 2014 Section 01: General Page 14
    Part 10: Occupational Health and Safety

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

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

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

    18 The Safety Plan shall detail the arrangements for notification and investigation of any incident

    l .
    that may occur as a result of Work or on the Worksite.

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    19 The Safety Plan shall detail the arrangements for the Contractors monthly performance
    reporting and incident reporting.

    20
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    The Contractor shall ensure that their project monthly health and safety statistics report is
    completed and submitted by the agreed date to the Engineer and Quality & Safety
    qa
    Department. The Engineer will provide the necessary format for this report. The information
    collected will be submitted to the Engineer and Quality & Safety Department.
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    21 The Safety Plan shall detail the arrangements for assessing the general Health of employees
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    and any job specific Health checks that may be required.

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


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    23 The Safety Plan shall detail the arrangements for tracking and effectively closing any
    Occupational Health and Safety related nonconformity or deficiency that may be identified as
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    a result of monitoring. Written records of inspection, auditing and tracking shall be


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    maintained and made available to any representative of Client on request.


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    24 The Safety Plan shall detail the arrangements for ensuring that all Contractor Personnel and
    m

    Subcontractor employees are trained and competent to undertake their work in accordance
    with the required standards. In particular the Safety plan shall detail the training and
    competence requirements for the following employees;

    (a) Supervisors
    (b) Electricians
    (c) Mobile plant and vehicle operators
    (d) Crane and lifting appliance operators
    (e) Riggers
    (f) Excavation Supervisors
    (g) Machinery operators
    (h) Scaffolders
    QCS 2014 Section 01: General Page 15
    Part 10: Occupational Health and Safety

    (i) Scaffolding Supervisors


    (j) Confined space workers
    (k) Confined space supervisors
    (l) All persons working at height

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

    26 The Safety Plan shall detail the Contractors arrangements for promoting the awareness of

    .
    Occupational Health and Safety issues through notices, posters, newsletters, booklets,

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    .l.
    Occupational Health and Safety alerts and any other means. All such information shall be
    provided in the languages preferred by the training recipients of the training.

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

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

    Suitability of the Contractors Occupational Health and Safety organization for the on-
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    (a)
    going and planned Work;
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    (b) Effectiveness of the Contractors Occupational Health and Safety management


    system;
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    (c) Significant areas of planned activity and associated risk;


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    (d) Method statement review and job hazard analysis planning;


    (e) Tracking and closure of any identified deficiencies or nonconformities;
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    (f) Incident review;


    (g) Occupational Health and Safety promotion planning;
    (h) Training needs assessment;
    (i) Auditing and inspection planning;

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

    (a) Front Cover


    (b) Table of Contents
    (c) Project Scope, Requirements and Occupational Health and Safety Objectives
    QCS 2014 Section 01: General Page 16
    Part 10: Occupational Health and Safety

    (d) Occupational Health and Safety Policy and BS OHSAS 18001 Certificate (if applicable)
    (e) Control of Occupational Health and Safety Plan
    (f) Reference Documentation
    (g) Safety Organisation and Responsibilities
    (h) Subcontractor Occupational Health and Safety
    (i) Risk Assessments and Method Statement
    (j) Non-conformance, Corrective and Preventative Action
    (k) Incident Reporting
    (l) Audits
    (m) Training

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    (n) Key Performance Indicators and Continual Improvement

    .l.
    (o) Management Review

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    (p) Safety Meetings
    (q) Monthly Safety Report
    (r) Appendices ta
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    10.2.2 Occupational Health and Safety Policy
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    1 The Contractor shall comply with the Client vision, mission and strategic objectives.
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    2 The Contractor shall develop and implement its own written Occupational Health and Safety
    Policy which shall be Project specific and demonstrate the Contractors understanding of and
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    commitment to maintaining standards of Occupational Health and Safety (OHS) that are
    consistent with and an integral part of the Contractors business strategy.
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    3 The Contractor must set objectives and targets that shall be applicable to SMART - Specific,
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    Measurable, Achievable, and Realistic and to a Time scale.


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    et

    10.2.3 Risk Assessment and Job Hazard Analysis


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

    10.2.4 Intervention

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

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

    3 The Contractor is required to acknowledge that the system of positive intervention in use on
    the Project is one that shall enhance the following;
    QCS 2014 Section 01: General Page 17
    Part 10: Occupational Health and Safety

    (a) levels of understanding and awareness of Occupational Health and Safety issues
    throughout the Project;
    (b) levels of personal responsibility and accountability for Occupational Health and Safety
    issues;
    (c) levels of proactively towards Occupational Health and Safety issues;
    (d) levels of compliance with contractual requirements and Project Occupational Health
    and Safety standards;
    (e) incident and injury prevention

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

    l .
    that may be required to address any nonconformity identified during such auditing.

    .l.
    rw
    5 The Contractor may be the focus of Occupational Health and Safety inspections conducted
    by any representative of Client. The Contractor is required to cooperate with and
    acknowledge such inspections and take all corrective and preventive actions that may arise
    as the result of such inspections.
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    qa
    6 The Contractor shall undertake routine Occupational Health and Safety inspections and
    audits for the on-going Work. Written records of inspections and audits shall be maintained
    as

    and made available to any representative of Client upon request.


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

    8 The Contractor shall stop work if any unknown or unplanned conditions occur that give rise to
    serious or imminent danger. In such circumstances the Contractor shall assess the risks
    o

    associated with any remedial work required and revise the method statements and job
    it

    hazard analysis. The revised method statement shall be reviewed and approved by the
    et

    Contractors Occupational Health and Safety Manager. Revised method statements shall be
    approved by the Engineer before recommencing Work.
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    10.2.5 Requirement for Training

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

    2 The Contractor is required to provide employees of Client with Occupational Health and
    Safety training relating to Work undertaken by the Contractor. Training is an integral part of
    job performance.
    QCS 2014 Section 01: General Page 18
    Part 10: Occupational Health and Safety

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

    4 The Contractor shall appoint a competent supervisor for each and every area of the following
    Work activities

    (a) Temporary & permanent electrical installation


    (b) Crane and lifting appliance operations
    (c) Scaffolding erection, alteration and dismantling

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    (d) Confined space entry

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    (e) Excavation

    rw
    (f) Working at height

    5 The Contractor shall produce a health and Safety Training Matrix based on training needs

    ta
    analysis of all personnel working on the project. The matrix must detail positions against the
    qa
    training courses required from the analysis. All training courses provided to employees shall
    be free of charge, i.e. the cost will be borne by the Contractor.
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    6 The training topics will be based on a number of factors, such as but not limited to;
    se

    (a) Trends in monthly statistics;


    (b) Objectives that have been set;
    er

    (c) Recurring issues on site; and


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    (d) Accident/incidents on site.

    7 Courses designed to meet the needs of specific operatives involved in specialized trades
    o

    including their roles and responsibilities must be provided through training. The following
    it

    training could be consider as specialist, but not limited to:


    et

    (a) Safe entry into confined spaces;


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    (b) Crane operation;


    (c) Slingers/banks men;
    (d) Scaffolding/ false work/temporary works;
    (e) Abrasive wheels;
    (f) Woodworking machinery;
    (g) Excavation support equipment;
    (h) First aid;
    (i) Fire Marshall;
    (j) Accident Investigation;
    Note any external training must be delivered by a competent organisation (i.e. 3th
    Party).
    QCS 2014 Section 01: General Page 19
    Part 10: Occupational Health and Safety

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

    (a) Occupational hygiene.


    (b) Essential elements of local laws and regulations.
    (c) Policies and procedures concerning aspects of human rights those are relevant to
    operations.

    9 The Contractor shall actively encourage the following for their workforce:

    (a) Creating employment opportunities.


    (b) Facilitating training opportunities for employees with a view to improving skill levels.
    (c) Ensuring non-discrimination in hiring and promotion practices.

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    (d) Promoting life-long learning and on-the-job training.

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

    10
    ta
    The Contractor shall retain records of all training provided to labour accommodation
    residents. Such records shall include, as a minimum, the name, age and nationality of those
    qa
    attending the training course/session and the type of training provided. These records shall
    be available for inspection by the Engineer.
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    11 The Contractors shall conduct Emergency Drills to thoroughly test its emergency
    se

    preparedness and response within 6 months of the date of award of the Contract and
    thereafter at periods not exceeding 6 months throughout the duration of the Work.
    er

    12 The Contractor shall hold a Contract Specific Occupational Health and Safety Meeting
    ov

    chaired by the Contractors representative on a monthly basis throughout the duration of the
    WORK. Additionally the Contractor shall include Occupational Health and Safety as an item
    on the agenda for each and every meeting held and ensure that the subject is actively
    o

    discussed.
    it
    et

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

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

    10.3 EMERGENCY RESPONSE PLAN (ERP)

    10.3.1 General

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

    (a) Responsibilities;
    (b) Risk assessment and hazard identification and controls for potential emergencies;
    QCS 2014 Section 01: General Page 20
    Part 10: Occupational Health and Safety

    (c) Hazard identifications and controls;


    (d) Coordination with outside emergency response organizations;
    (e) Arrival of outside emergency response groups;
    (f) Emergency response equipment;
    (g) Emergency drills;
    (h) Tests of emergency preparedness and response program;
    (i) Crisis management plan - major events emergency response plan;
    (j) Evacuation procedure;
    (k) Medical facilities;
    (l) Site fire prevention and response reporting;

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    (m) Environmental spills and releases;

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    (n) Security including (bomb threat);

    rw
    (o) Malicious threats; and
    (p) Severe weather conditions.
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    qa
    2 It shall be mandatory that all personnel are aware and understand what actions to take and
    when to take them in the event of an emergency situation. The Contractor shall provide such
    as

    information, instruction and training as may be required to assist the personnel to respond
    appropriately, in the event of an emergency.
    se

    3 The Contractor shall develop ERPs for review by the Engineer in order to verify the suitability
    er

    and capability of arrangements. The Contractor shall ensure a schedule is produced to


    conduct drills and exercises on a regular basis at the sites under its control.
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    4 Records of drills and exercises conducted shall to be kept together with details of follow up
    actions and performance assessments for audit purpose.
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    5 The first emergency drill shall be conducted within first the 30 calendar days following
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    commencement of operations; afterwards emergency drills shall be conducted on a 6


    monthly basis as a minimum.
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    6 All ERPs shall be reviewed and whenever necessary revised and updated every 6 months,
    periodic auditing must be carried out to ensure compliance.

    10.4 EARTHQUAKE EMERGENCY MANAGEMENT PLAN

    10.4.1 Background

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

    2 April 16th 2013 was by far the larger earthquake measuring 7.8 on the Richter scale with the
    tremors physically being felt in numerous locations and buildings across the region. Whilst
    events of this type are rare, the impacts could be serious both from a human and business
    scale.
    QCS 2014 Section 01: General Page 21
    Part 10: Occupational Health and Safety

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

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

    10.4.2 Requirements

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

    2 The suggested overall approach would be a three phase priority approach. The first phase

    .
    identifying the as is situation to the desired outcome of to be and the future requirements,

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    but this is not limited and may require additional elements as recommended by other experts.

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    10.4.3 Phase One: Gap Analysis (as is)

    1
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    Engage the relevant technical experts for the various aspects of the review, inclusive of but
    not limited to Fire Design Engineer, Health and Safety Consultant, training providers etc.
    qa
    2 Review all existing emergency process, procedures, plans and protocols within the
    organisation and engage with other stakeholders such as Civil Defence to understand any
    as

    wider requirements, etc.


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

    4 Review all evacuation assembly points and engage other building owners nearby the
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    organisation building.
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    5 Develop work assignments for the organisation personnel and Safety Wardens during
    it

    earthquakes.
    et

    6 Review the organisation buildings maintenance department records.


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

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

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

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

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

    12 Review existing crisis management plans, process and procedure.


    QCS 2014 Section 01: General Page 22
    Part 10: Occupational Health and Safety

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

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

    15 Undertake training and awareness for any developed process and procedures.

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

    17 Present outcomes of gap analysis.

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

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

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    10.4.4 Phase Two: Implementation (to be)

    1
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    Implement agreed gap analysis outputs/approach inclusive of all manuals, procedures,
    technical information required.
    qa
    2 Develop administrative processes and procedures to support the plan.
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    3 Communicate the plan to all those affected at different level of the business.
    se

    4 Include for planning of any associated drills and lessons learnt.


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    5 Implement lessons learnt into plan, processes and procedures.


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    6 Establish periodic review of emergency systems.

    10.4.5 Phase Three: Future Requirements


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    1 Advise if engagement of further consultants/engineers to undertake seismic survey of


    et

    existing buildings.
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    2 Development of business continuity plans.

    3 Development of post-earthquake assessment procedures.

    4 Development of crisis management plans.

    5 Undertake training and awareness for any developed process and procedures.

    6 Include for planning of any associated drills and lessons learnt.

    7 Development of all related support materials.

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

    9 Periodic review of emergency planning systems.


    QCS 2014 Section 01: General Page 23
    Part 10: Occupational Health and Safety

    10.4.6 What Should We Do During An Earth Quake?

    1 Stay calm!

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

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

    4 Drop down onto your hands and knees.

    5 Stay away from windows and outside doors.

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

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

    rw
    8 Broken gas lines and fire don't mix.

    9
    ta
    If you're in a car, stop the car and stay inside the car until the earthquake stops.
    qa
    10 Don't use elevators or put yourself at risk.

    11 For impaired mobility, if you cannot drop to the ground, try to sit or remain seated so you are
    as

    not knocked down. If you are in a wheelchair lock your wheels. Protect your head and neck
    with a large book, a pillow, or your arms.
    se

    10.4.7 What Should We Do After An Earth Quake?


    er

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

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

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

    4 Stay out of damaged buildings.

    5 Stay inside buildings unless directed to do otherwise.

    6 Evaluate and critique once a crisis situation is stabilised.

    7 Expect further aftershocks.

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

    9 If you're at work follow the emergency arrangements and instructions for the particular
    building after the earthquake.
    QCS 2014 Section 01: General Page 24
    Part 10: Occupational Health and Safety

    10.5 SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS

    10.5.1 Permits

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

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

    10.5.2 Guarantee

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

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    Works Authority.

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    rw
    10.5.3 Mechanical Plant, Machinery and Equipment

    1 Sufficient suitable standby plant shall be immediately available in cases where the safety of

    ta
    the Works or of personnel depends upon mechanical plant.
    qa
    2 Test and thorough examination by a competent person of all equipment that is capable of
    storing energy, such as air receivers and pressure vessels, is required at periods not
    as

    exceeding 12 months. Reports of such test and examination will be held on the Worksite and
    made available to the employer on request.
    se

    3 The Contractor will make arrangements for all mobile plant and vehicles that enter the
    er

    Worksite to be checked by 3rd party certification to ensure the following are provided and in
    good working order:
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    (a) Braking systems


    (b) Steering systems
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    (c) Gauges and warning lights


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    (d) Operating controls


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    (e) Windscreens and wipers


    (f) Reversing alarms
    (g) Rear view mirrors
    (h) Roll over protection devices
    (i) Wheels, tyres, track
    (j) Pneumatic and hydraulic hoses
    (k) Seat belts and anchors
    (l) Fuel lines and tanks
    (m) Electrical control systems
    (n) Suspension and stabilization systems
    (o) Bodywork, covers and panels
    QCS 2014 Section 01: General Page 25
    Part 10: Occupational Health and Safety

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

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

    6 Whenever maintenance work is ongoing the machinery or equipment will be isolated and de-
    energized.

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

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

    l .
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    9 The Contractor will conduct a job hazard analysis for each item of machinery and equipment

    rw
    that will be used.

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

    (a) ta
    Mobile plant and delivery vehicles will not be reversed without a banks man in
    qa
    attendance.
    (b) No passengers will be carried on mobile plant or vehicles other that in seats that are
    as

    specifically designed for carrying passengers.

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

    12 The Contractor will eliminate or reduce the associated hazards for construction lift such as,
    er

    construction lift failure, falling persons and falling objects by meeting or bettering these
    ov

    specifications. And:

    (a) All construction lifts will have flat base plates without holes or openings, enclosed sides
    o

    and roof that are designed to prevent from falling objects.


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    (b) All construction lifts will have overload protection devices that prevent movement of the
    et

    platform if it is overloaded.
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    10.5.4 Existing Utilities

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

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

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

    (a) Marker posts or blocks that clearly indicate the nature, depth and path of all
    underground utilities.
    (b) Where traffic routes pass over underground utilities temporary protection will be
    provided. Warning signs stating the maximum vehicle weight that may safely cross the
    utility will be positioned on the access route at each side of the utility.
    QCS 2014 Section 01: General Page 26
    Part 10: Occupational Health and Safety

    (c) Temporary barriers or fences that run parallel to the route of any overhead utilities.
    Warning signs detailing the nature of any overhead utilities on the barriers or fences.
    (d) Where traffic routes pass below overhead utilities warning signs stating the maximum
    vehicle height and height restrictors will be positioned on the access route at each side
    of the overhead utility.

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

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

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    10.5.5 Excavations

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

    (a) Shoring
    ta
    qa
    (b) Solid Barriers
    (c) Vehicle stop blocks
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    (d) Access ladders or scaffolding


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    (e) Ventilation
    (f) Lighting
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    (g) Signage
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    (h) Pumps
    (i) Generators
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    (j) Air Monitoring Devices


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    et

    (k) Movement Monitoring Equipment


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    (l) Rescue Equipment

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

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

    4 Once the design requirements are known a job hazard analysis of the excavation work will be
    completed by the excavation supervisor with the assistance of Occupational Health and
    Safety staff and engineers as required. The Job Hazard Analysis will clearly identify the job
    specific risks and control measures for the excavation work.
    QCS 2014 Section 01: General Page 27
    Part 10: Occupational Health and Safety

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

    6 Prior to commencement of work all materials, plant and equipment will be checked to ensure
    that they are in good condition. In particular the condition of all mechanical excavators will be
    checked to ensure that:

    (a) All windows in the drivers cab are clean, unbroken and unobstructed.
    (b) Rear view mirrors are securely attached, unbroken and clean.
    (c) All track plates and connectors are in good condition and secured with proprietary
    locking pins.

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

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    .l.
    pins.

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    (e) All task and indicator lighting is in working order.

    7 Trucks will only be operated by persons with valid Qatari driving licenses. Plant such as

    ta
    excavators, loading shovels etc shall only be operated by trained and competent operators
    that hold valid 3rd Party certification for the type of plant being operated. This certification is
    qa
    required in addition to Qatari driving license requirements.

    8 When the reversing of trucks is necessary for the collection or delivery of materials a banks
    as

    man will be in attendance. All banks men will be provided with high visibility clothing and be
    trained in the safety aspects of reversing vehicles. Where vehicles are reversing up to an
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    excavation or travelling alongside an excavation vehicle stop blocks or vehicle barriers will be
    provided to prevent them falling into the excavation.
    er

    9 Continuous adequate solid barriers will be placed around all excavations over 1.2m deep at a
    ov

    distance at least of 1.2m. Where night time pedestrian or vehicle access is adjacent to
    excavation then all solid barriers will be fitted with warning lights.
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    10 Pedestrian access to and from all excavations will be by means of ladder or adequately
    et

    constructed staircases. The possibility of a person falling from a height of more than 2m from
    the access will be prevented. The horizontal distance between access points will not exceed
    m

    15m.

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

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

    13 Ladders that are used to gain access from one level to another will extend at least 1m above
    the upper level surface. Where a general access ladder run extends a distance of more than
    6m a landing point with a firm level platform and fall prevention measures will be provided at
    each and every 6m.
    QCS 2014 Section 01: General Page 28
    Part 10: Occupational Health and Safety

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

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

    10.5.6 Warning Signs

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

    2 Additional areas that require warnings signs and barriers are:

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    (a) Excavations over 1.2m deep

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    (b) Any edge, opening or platform from where a person may fall more than 2m
    (c) Electrical transformers and substations
    (d) Confined space entry points
    ta
    qa
    (e) Areas below and around working at height and heavy lifting operations
    (f) Areas of open water more than 1m deep
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    (g) Areas where flammable goods are stored


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    (h) Areas where radiation sources are used or stored


    (i) Areas within Worksites that are classed as non-construction areas
    er

    (j) Areas within non construction areas where construction activity is on-going
    ov

    (k) Areas below overhead utilities


    (l) Areas above underground services
    it o

    (m) Areas where test and commissioning activities are on-going


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    3 Warning signs will clearly state the nature of the hazard and instruct people of the correct
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    actions to take. Warning signs will be manufactures in accordance with internationally


    recognised standards. All signs will be in English, Arabic and the languages preferred (can
    be understand) by the workers on the Worksite.

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

    10.5.7 Confined Spaces

    1 Entry into a confined space will only be permitted where a competent person is appointed to
    directly supervise the work. The competent person will hold a certificate of training or license
    that is issued by a 3rd party. The competent person will be appointed in writing by the
    Contractor and the appointment will be copied to the employer.
    QCS 2014 Section 01: General Page 29
    Part 10: Occupational Health and Safety

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

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

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

    5 Internal combustion engines will not be taken into a confined space or operated in a position

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    where their exhaust gasses may be drawn into the confined space.

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

    7
    ta
    The contractor will implement a safe working procedure for confined space entry that
    includes the following:
    qa
    (a) Preparation of a confined space entry permit
    as

    (b) Provision of all equipment necessary for entering into and working in the confined
    space including access, lighting, mechanical ventilation, gas detectors,
    se

    communication, personal protective equipment and emergency rescue equipment. All


    such equipment will be manufactured in accordance with internationally recognised
    er

    standards
    (c) Provision of warning signs and barriers around the confined space entry point
    ov

    (d) Setting up emergency communication and rescue equipment


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    (e) Issue of a permit to enter the confined space


    it

    (f) Checking of the atmosphere inside the confined space and installation of ventilation
    et

    equipment
    m

    (g) Installation of lighting


    (h) Entry into and work in the confined space.
    (i) Monitoring of conditions in the confined space.
    (j) Continuous checking and recording of all persons entering into and exiting from the
    confined space by the confined space attendant
    (k) Completion of work and removal of all equipment from the confined space
    (l) Accounting for all persons and equipment that entered the confined space
    (m) Securing the entry point to the confined space
    (n) Closing the confined space entry permit
    QCS 2014 Section 01: General Page 30
    Part 10: Occupational Health and Safety

    10.5.8 Lifting Operation

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

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

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

    4 A thorough examination of each lifting appliance will be made by a 3rd party inspector at

    l .
    periods not exceeding 12 months and after substantial re-erection, alteration or repair. Load

    .l.
    capacity to be displayed.

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

    6 ta
    Before a mobile crane is positioned for a lift, attention will be paid to the condition of the
    qa
    ground upon which the crane will stand, as this will be subjected to high point-loadings from
    outriggers or tyres. Dependent upon the nature of the ground and/or the size of the crane to
    as

    be used, a special hard standing may have to be prepared.


    se

    7 The maximum safe working wind speeds for all construction activity and in particular lifting
    operations and Working at height activity is 25 Knots. The construction will monitor the
    er

    weather conditions and suspend work when wind speeds in excess of the maximum safe
    working speeds are anticipated.
    ov

    8 Outriggers will be properly set and locked if a locking device is provided. When controlled
    remotely from the cab, the operator will make a physical check to ensure that each pad has
    o

    an adequate bearing before a load is lifted. Sound timber packing or metal plates will be used
    it

    under each outrigger pad to distribute the load. It is essential that outriggers are supported at
    et

    the jacking points and not under the outrigger beams. Also, lifting location to be barrier off.
    m

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

    10.5.9 Lifting Gear

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

    2 All lifting gear will be subjected to a thorough examination by a competent person from 3rd
    party at intervals not exceeding 6 months. Identity number and SWL to be check.
    QCS 2014 Section 01: General Page 31
    Part 10: Occupational Health and Safety

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

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

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

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

    10.5.10 Scaffolding

    l .
    1 For all scaffolding construction activity and dismantling activity a competent scaffolding

    .l.
    supervisor will be appointed. The level of training and experience required to determine

    rw
    competence will vary depending on the complexity of the scaffolding structure to be erected
    or dismantling. Industry standards and codes detail competency requirements.

    2
    ta
    All employees involved in scaffolding construction activities and dismantling activity will be
    trained in the safe methods of working and in particular the manner in which fall prevention or
    qa
    arrest is to be achieved. Contractors will maintain detailed information of the training provided
    and the methods that they have used for assessment of competency and suitability for all
    as

    employees undertaking scaffolding construction activities.


    se

    3 All scaffolding erection areas and dismantling areas will be provided with barriers and
    warning signs to exclude all personnel that are not specifically involved with the scaffolding
    er

    construction and dismantling activity. Where such areas are adjacent to roadways barriers
    with a capability to prevent vehicles entering the area will be erected or dismantling. Where
    ov

    such areas are adjacent to members of the public or 3rd parties then screening and falling
    object protection will be provided. The appointed scaffolding supervisor is to be made
    responsible for ensuring that exclusion zones are in place and maintained at all times whilst
    o

    scaffolding construction and dismantling activity is on-going.


    it
    et

    4 All materials being used for scaffolding construction will be checked prior to them being used
    to ensure they are in good condition. Any materials found to be defective will be clearly
    m

    marked as defective and discarded or removed from the construction area to ensure that
    they are not used.

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

    (a) the unique identification and location of the scaffolding inspected


    (b) the name of the person making the inspection
    (c) the date that the inspection was completed
    (d) the intended use and capacity of the scaffolding
    (e) the required re-inspection frequency for the scaffolding

    6 The person making the scaffold inspection will maintain written details of the inspection that
    they have conducted to enable them to verify their scaff tag system.
    QCS 2014 Section 01: General Page 32
    Part 10: Occupational Health and Safety

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

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

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

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

    11 The frequency of re-inspection of scaffolding every 7(seven) days will be displayed on the

    l .
    green scaff tag. Users of scaffolding are required to check that the period of re-inspection

    .l.
    has not been exceeded before using the scaffolding. In any case where the re-inspection

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    date has been exceeded the user will request the appointed scaffolding supervisor to make
    the re-inspection and to re-sign the green scaff tag for use. The user will not access the
    scaffolding until such time as the re-inspection has been made.

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


    se

    1 The contractor will only use electric welding equipment in accordance with the following
    er

    requirements:

    (a) Welding cables and equipment will be properly maintained and inspected before use.
    ov

    Defective equipment will be removed from use and arrangement for repair will be
    made.
    o

    (b) Electric welding cables are to be kept as short as possible and routed away from
    it

    pedestrian walkway areas.


    et

    (c) Electric welding operations will only be undertaken with earth return electrodes
    m

    connected to the work piece.


    (d) All connections between welding equipment and welding cables will be securely bolted.
    (e) Pipelines containing flammable liquids or gases, or electrical cables will not be used as
    a ground.
    (f) When electrode holders are to be left unattended, the electrodes will be removed and
    the holder placed where it is protected from unintentional contact.
    (g) A fire resistant container will be provided for spent electrode stubs.
    (h) Welding machines will be turned off when being moved or when the equipment is not
    in use.

    2 Tanks, vessels and drums that have contained flammable or toxic liquids will be filled with
    water or thoroughly cleaned before hot work or welding is undertaken on them.
    QCS 2014 Section 01: General Page 33
    Part 10: Occupational Health and Safety

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

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

    10.5.12 Compressed Gas Cylinders

    1 The Contractor will only use compressed fuel gasses in accordance with the following
    requirements;

    (a) Cylinders will not be transported with regulators, gauges and hoses attached.
    (b) Cylinders will be transported in an upright position and will not be hauled in equipment
    beds or truck beds on their side.

    .
    (c) Cylinders lifted from one elevation to another will be lifted only in racks or containers

    l
    .l.
    designed for that purpose. Cylinders will not be hoisted by the valve cap or by means
    of magnets or slings.

    rw
    (d) Cylinders will not be used as, or placed where they may become part of, an electrical
    circuit.
    (e) ta
    Cylinders will be protected from extreme heat and from being struck by moving
    qa
    equipment and falling objects.
    (f) Cylinders will not be taken into a confined space.
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    (g) Cylinders will not be used as rollers; will be transport on appropriate trolley.
    se

    (h) Damaged or defective cylinders will not be used or be permitted to remain on the
    Worksite.
    er

    (i) Type of gas clearly marked on cylinders and segregation of incompatible gases is
    required.
    ov

    (j) Oxygen cylinders will be kept free of oil and grease.


    o

    (k) Cylinders will be secured in place during use and storage. Securing shall be around
    it

    the body of the cylinder, securing around the cylinder neck or cap will be prohibited.
    et

    (l) Cylinder valves will be closed at all times when cylinders are not in use.
    m

    (m) A key wrench is required to be in place on the valve of acetylene cylinders at all times
    during use.
    (n) Fuel gas and oxygen hoses will be of different colours and will not be interchanged.
    (o) All hose, valve and regulator assemblies will incorporate a flashback arrestor.
    (p) Hoses are to be kept as short as possible and routed away from walkway areas.
    (q) Under no circumstances are damaged hoses or torches to be used.
    (r) Torches will be ignited by friction lighters or other approved devices only.
    (s) Fuel gases will only be used for the purposes of cutting or heating. They will never be
    used for pressure testing or ventilation.
    QCS 2014 Section 01: General Page 34
    Part 10: Occupational Health and Safety

    10.5.13 Working at Height

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

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

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

    4 Safe access to the point at which a person will attach themselves to a fall arrest system will
    be provided. In cases where a person using a safety harness has to detach the lanyard from

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    the anchor point and reattach it to a different anchor point, whilst being in a position where

    .l.
    the risk of falling exists, double lanyards will be used with one of the lanyards remaining

    rw
    attached to the anchor point at all times.

    5 Where any form of fall arrest system is used the contractor will put in place arrangements to

    ta
    rescue any person that is caught by the fall arrest system. The rescue system and equipment
    will be capable of rescuing any person that may be unconscious whilst suspended and or
    qa
    suffering from suspension trauma. The system will be capable of rescuing the suspended
    person within 3 minutes of the fall being arrested.
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    6 All edges of working platforms and work areas that objects may fall from will be provided with
    se

    securely fixed continuous toe boards that are at least 200mm high.
    er

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

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

    from them.
    it
    et

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

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

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

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

    (a) Fragile coverings


    (b) Holes and openings
    QCS 2014 Section 01: General Page 35
    Part 10: Occupational Health and Safety

    (c) Exposed edges


    (d) Lack of safe access
    (e) Damage or disrepair of the existing structure
    (f) Adjacent structures, facilities or services

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

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

    l .
    (a) The storage of materials on roof surfaces will be minimized at all times

    .l.
    (b) Storage of materials on roof surfaces is not permitted within 2m of any edge or eave

    rw
    (c) All openings and non-walkable areas will be protected by barriers and signage to
    prevent pedestrian access
    (d) ta
    All waste will be removed from the work areas on a daily basis and prior to any areas
    qa
    being left unattended
    (e) All areas of roof or canopy covering will be fully fixed at the time of positioning. The
    as

    practice of laying large areas of unfixed coverings is prohibited

    15 The structure that the suspended working platform is attached to or mounted on will be
    se

    surveyed and assessed to ensure that it is capable of supporting the loads that the
    equipment will impose on it.
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    16 The installation, maintenance, use and dismantling of suspended working platforms will be
    ov

    under the control of a competent person that is appointed by the Contractor. The competent
    person will be fully familiar with each and every type of suspended working platform in use on
    o

    the Worksite. Persons who work from suspended working platforms will have received formal
    it

    training to ensure the safety of themselves and of other persons that may be affected by the
    et

    operation with particular emphasis on the correct use of the equipment, working at height and
    falling object prevention.
    m

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

    (a) Users will not alter or interfere with any part of the suspended working platform, control
    or safety devices.
    (b) The work area below the suspended working platform will be clearly marked a
    pedestrian exclusion zone will be created.
    (c) The user will check all controls and safety devices on a daily basis to ensure that they
    are functioning correctly.
    (d) Use will cease whenever wind speed in excess of the maximum permissible is
    anticipated.
    (e) The suspended working platform will be maintained in a horizontal position whilst it is
    in use.
    QCS 2014 Section 01: General Page 36
    Part 10: Occupational Health and Safety

    (f) The practice of transferring people or materials from the suspended working platform
    is prohibited other than at the designated access points.
    (g) Every person working from a suspended working platform shall wear a full body safety
    harness that is attached to an independent lifeline.
    (h) The platform will be kept free of loose materials or articles liable to endanger or
    interfere with the workers hand hold or foot hold
    (i) The power supply will be disabled whenever the suspended working platform is left
    unattended.

    10.5.14 Electrical

    1 This specification applies to all temporary electrical systems on the Worksite and all electrical
    equipment used for construction, commissioning and testing purposes. The requirements

    .
    given are minimum requirements and Contractors are required to equal or better them.

    l
    .l.
    2 A competent electrician or electrical engineer will be appointed or employed on every

    rw
    contract. The competency requirements will be determined by the nature of the temporary
    electrical system that will be installed on the Worksite

    3
    ta
    The Contractor will reduce risk by using cordless tools or electrical equipment that is
    qa
    operated at reduced voltages. Only intrinsically safe electrical equipment will be permitted for
    use at any location where flammable atmospheres may exist or confined space.
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    4 All electrical equipment used on the Worksite will be manufactured in accordance with an
    internationally recognised standard.
    se

    5 Portable Power Tools will be of a double insulated type.


    er

    6 Jointing of all electrical cables and wires shall be by means of proprietary terminations or
    ov

    connectors. The practice of twisting and taping electrical components together to create a
    connection is prohibited.
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    7 Temporary power supplies for the Worksite may be provided from generators or via a
    it

    Worksite specific transformer connected to the national power network. All generators and
    et

    transformers on the Worksite shall be located in areas that are fenced and secured to
    m

    prevent any unauthorized entry. Each such location will be provided with portable fire
    extinguishers. All electrical systems shall be bonded to the earth.

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

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

    10 All signs and notices shall be in English and Arabic and the language preferred (can be
    understand) by the workers employed on the Worksite.
    QCS 2014 Section 01: General Page 37
    Part 10: Occupational Health and Safety

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

    10.6 FIRST AID

    10.6.1 First Aid and Clinic

    1 The Contractor shall provide and maintain first aid Boxes / Clinic (according to number of
    workers as per Qatar Law No.14 of the Year 2004 The Labour Law) complete with all first

    .
    aid kits and equipment (as a minimum but not limited to Clean room with potable water

    l
    .l.
    supply, Stretcher, Ambulance, Standby Vehicle, ... etc) necessary for the initial care of any of
    the Contractors or Engineers personnel who may be injured.

    rw
    2 The box shall be kept in a conspicuous place in the establishment and shall be available to
    the workers.
    ta
    qa
    3 The use of the box shall be entrusted to a worker trained in providing first-aid medical
    services.
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    4 As a minimum, there should be a first aid box with Medical record book in all areas where
    work is in progress.
    se

    5 The Contractor shall ensure that the first aid Kits and equipment at each first aid box / clinic
    er

    is complete and within expiration date in all respects at all times.


    ov

    6 At each first aid box / clinic the names and contact Telephone numbers of the Contractors
    staff who are trained to render first aid shall be displayed.
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    7 The Contractor shall provide and maintain Periodic medical examinations for workers and
    it

    follow up (maximum every year from employment date).


    et
    m

    10.7 FIRE PRECAUTION AND PREVENTION

    10.7.1 General

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

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

    3 All flammable materials storage areas will be located at least 20m away from other
    structures, areas where combustible materials are stored and areas where sources of ignition
    are found. Storage areas will be freely ventilated to eliminate any possible build up of
    flammable vapour or gas. Flammable material storage facilities will not be constructed of
    combustible materials.
    QCS 2014 Section 01: General Page 38
    Part 10: Occupational Health and Safety

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

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

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

    7 Combustible fuel oils shall be stored in designated storage areas. Fuel oil shall only be
    contained in tanks or containers that are in good condition. Tanks and containers will be

    l .
    located in bounded areas capable of containing any spillage or leak. Bounded areas will be

    .l.
    kept free of water and debris. All pump equipment and fuel oil lines or hoses will be

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    maintained regularly to ensure that there no leaking parts. Fuel oil lines and hoses will be
    terminated with filler nozzles or valves that stop the flow of fuel oil when the device is not
    held. Any electrical equipment such as lighting and pumps that is located in fuel oil storage

    ta
    areas shall have an operating voltage of 110V or less.
    qa
    8 Hot work and welding operations at height require particular controls to prevent people or
    materials below being exposed to the risks of the work activity, the following controls will be
    as

    put in place;

    (a) All work activity will be coordinated with other activities in areas below
    se

    (b) Areas below will be cleared of all combustible and flammable materials.
    er

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

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

    (e) A fire watchman will remain at the site of hot work activity for 30 minutes after work is
    it

    finished.
    et

    9 The Contractor will provide training in the correct selection and use of portable fire
    m

    extinguishers for every person employed at the Worksite.

    10 Portable fire extinguishers will be provided at the following locations:

    (a) Every electrical generator, transformer and main distribution panel


    (b) Every piece of mobile plant and equipment
    (c) Every area of flammable materials storage and use
    (d) Every area of hot work activity
    (e) Every temporary structure
    (f) Every work area where combustible materials are present.

    11 Smoking will be prohibited in any areas where flammable or combustible materials are
    stored. It will also be prohibited in any temporary structure other than in clearly designated
    and defined smoking areas. Smoking areas will be cleaned on a daily basis, a means of
    extinguishing cigarettes will be provided.
    QCS 2014 Section 01: General Page 39
    Part 10: Occupational Health and Safety

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

    13 Information and warning signs will be provided at the following locations or areas:

    (a) Flammable materials stores


    (b) Combustible materials stores
    (c) Temporary fire systems
    (d) Portable fire extinguishers
    (e) Fire escape routes, exits and assembly areas.

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

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    10.7.2 Emergency Equipment

    1
    ta
    Temporary fire protection equipment for the Worksite will be provided by the Contractor for
    qa
    the duration of the contract. Such equipment may include but is not be limited to:

    (a) Portable fire extinguishers


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    (b) Fire sand buckets


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    (c) Fire water storage and distribution systems


    (d) Fire suppression systems
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    (e) Fire / Smoke / Gas detection systems


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    (f) Fire warning / Alarm / Emergency Evacuation systems


    (g) Procedures
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    (h) Emergency contact telephone numbers / Communications


    et

    (i) Breathing apparatus and / or respirators (if applicable)


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    (j) Torches
    (k) Loud Hailer
    (l) Emergency lighting
    (m) Adequate and safe Emergency Exit / Doors are provided
    (n) Assembly / Muster point

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

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

    (a) Portable fire extinguisher equipment.


    (b) First aid kit.
    QCS 2014 Section 01: General Page 40
    Part 10: Occupational Health and Safety

    (c) Trained first aider.


    (d) Emergency contact information notices.
    (e) Telephone or radio communication equipment.

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

    (a) Smoke detectors


    (b) One first aid kit for each 25 people.
    (c) Designated emergency evacuation routes.
    (d) An emergency preparedness and evacuation plan.
    (e) An emergency alarm system.

    l .
    (f) An emergency evacuation drill at periods not exceeding 6 months.

    .l.
    (g) An area set aside for the heating and consumption of food.

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

    (a) A fire water system ta


    qa
    (b) An appointed nurse
    (c) Emergency lighting system
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    6 All temporary fire protection equipment will be manufactured, inspected, tested and
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    maintained in accordance with the Department of Civil Defence or internationally recognised


    standards.
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    10.7.3 Hazardous Substances


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

    and Safety obligations.


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

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

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

    (a) Maintain a register of all hazardous substances on the Worksite


    (b) Obtain Material Safety Data Sheets for all hazardous substances
    (c) Make an assessment of the health risks associated with the intended use of each
    hazardous substance
    QCS 2014 Section 01: General Page 41
    Part 10: Occupational Health and Safety

    (d) Provide the control measures required to reduce the risks identifies to acceptable
    levels. Acceptability will be based on internationally recognised best practices and
    standards
    (e) Train people that use, handle or transport hazardous substances in the associated
    risks and control measures
    (f) Provide routine health checks for employees that are exposed to hazardous
    substances
    (g) Provide appropriate spill containment and disposal Spill kit
    (h) Toxic/ hazardous substance correctly tagged/ labelled/ signage and secured
    (i) Adequate storage provided and Class B fire extinguisher near by

    10.8 SAFETY OF THE PUBLIC

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    10.8.1 Working in Public Areas

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    1 The Contractor must ensure that control measures are in place to protect the public,
    workforce and assets by providing appropriate lighting, fencing, barricades, and lockable

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    units. Adequate levels of security including the use of trained security guards will be required.
    The Contractor must also ensure appropriate warning signage is displayed and where
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    appropriate safe pedestrian walkways are identified and maintained.

    2 Safety and security procedures shall be implemented in accordance with the Qatar Work
    as

    Zone Traffic Management Guide and as required by the Department of Civil Defence and the
    police. These shall be included, as a minimum, warning signs and lights, adequate
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    barricades, railings, road hump for reduced & control speed and other safeguards as
    required by the nature and location of the work being undertaken.
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    3 Access to all properties shall be maintained by adequately sign posted diversions, temporary
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    bridges or other facilities.


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

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

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

    7 No electrical cables, hoses or pipes shall be routed along any staircase, ladder access or
    across any doorway. This applies to both temporary and permanent works.
    QCS 2014 Section 01: General Page 42
    Part 10: Occupational Health and Safety

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

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

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    10.9 WELFARE, SAFETY AND PROTECTION OF WORKMEN

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    10.9.1 General

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

    1 All the Contractors personnel shall be provided with safety helmets, eye protection and foot
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    protection. Safety helmets, eye protection and foot protection shall be worn at all times by all
    Contractors personnel on the Site except.
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    All the Contractors personnel shall be provided with gloves, hearing protection, safety
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    2
    reflecting vests, dust mask and other protective clothing suitable for the nature of work they
    are performing and their working environment (Shorts and sleeveless shirts are prohibited).
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    3 All the Contractors personnel shall wear high visibility clothing as the outer layer of clothing
    et

    at all times when working on a road or within a road works zone in accordance with the Qatar
    Work Zone Traffic Management Guide.
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    4 The need for other types of PPE will be identified by the contractor as part of their job hazard
    analysis or risk assessment process.

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

    10.9.3 Safety Equipment

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

    2 Adequate hard barricading, temporary bridges, temporary footpaths, lighting, warning tape
    and sign posting shall be provided at all excavations.
    QCS 2014 Section 01: General Page 43
    Part 10: Occupational Health and Safety

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

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

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

    6 The following basic safety equipment is required for any works in confined spaces and shall
    be supplied by the Contractor:

    (a) gas detectors/monitors complete with carrying case, rechargeable batteries and

    .
    battery charger, calibration kit, all to the approval of the Engineer; consumable items

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    and sensors to be replaced in accordance with the manufacturers recommendations

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    during the course of the Contract (2 No.)
    (b) full body rescue safety harness with lifelines and shackles (6 No.)
    (c)
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    lifting frame complete with fall arrest device (1 No.)
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    (d) constant flow escape breathing apparatus complete with storage cases (2 No.)
    (e) automatic positive pressure self-contained breathing apparatus complete with
    storage case (1 No.)
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    7 The Contractor shall maintain all safety equipment in good working order with up to date
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    calibration and test certificates where appropriate.


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


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    9 The Contractor shall provide and maintain in good working order one compressed air escape
    respirator set (Drger Saver Auto PP or similar) in the Contractors site office.
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    et

    10 One oxygen resuscitation unit shall be provided in the Contractors site office.
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    11 Truck or Trailer Mounted Attenuators (TMAs), or lorry mounted crash cushions must be used
    in accordance with the Qatar Work Zone Traffic Management Guide.

    10.9.4 Support Facilities for Contractors Staff and Labour

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

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

    3 Cooking and dining facilities that are provided will be operated and maintained in a clean and
    hygienic condition. Food preparation and storage areas will be separated from eating areas.
    QCS 2014 Section 01: General Page 44
    Part 10: Occupational Health and Safety

    (a) No person with any communicable disease will be permitted to work in any kitchen or
    dining room
    (b) Kitchen workers who have cuts or skin conditions on their hands will not be permitted
    to work in any kitchen or dining area
    (c) Kitchen workers that handle or serve food will wear latex gloves, hairnets and clean
    clothing.

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

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

    .
    6 The Contractor shall provide sufficient bins for waste and scrap regularly collected,

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    segregated and removed from site.

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    7 Arrangements for the temporary storage of waste on site shall be made in clearly designated
    and defined areas that have fences and signs to clearly indicate the nature of the waste

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    where combustible wastes are stored portable fire extinguishers will be provided.
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    8 Waste collection points will be provided throughout the work areas and will be clearly marked
    with signage to indicate the nature of the waste that is to be collected. Waste will be
    separated and collected in the following categories:
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    (a) Metals
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    (b) Oils
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    (c) Concrete & Stone


    (d) Tyre & rubber
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    (e) Glass
    (f) General
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    (g) Food
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    (h) Sewage
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    (i) Chemical

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

    (a) Any hazardous substances that are stored shall only be kept in accordance with the
    suppliers recommendations and the requirements of the Hazardous Substances
    Specifications.
    (b) Flammable materials and fuel oil storage areas must be separated from other
    temporary structures or works under construction by a distance of 30m.
    (c) Where materials are stored in stacks they will not be stacked to a height of more than
    1.5 m where the materials are to be manually handled. Materials for mechanical
    handling that are on pallets or contained in bins will not be stacked more that 3 units
    high with the base bin or pallet being on firm level ground.
    QCS 2014 Section 01: General Page 45
    Part 10: Occupational Health and Safety

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

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

    (a) Ergonomics and proper layout of work area.


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

    .
    (i) Temporary lighting for all Worksite access areas and roads that will be used

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    during the hours of darkness.

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    (ii) Task lighting for all work activity at night or in areas with poor visibility.
    (iii) Emergency lighting for pedestrian access routes in areas of poor visibility and
    those used during night time working.
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    qa
    (iv) Ensure the absence of glare.
    (v) Proper lighting in corridors.
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    10.9.5 Summer Working Conditions and fatigue


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    1 During the period from June 15th until August 31st, work under direct sun rays is prohibited
    from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control
    er

    and ease effect of the direct sun on the workers. This arrangement should be approved by
    the Engineers Representative and should be agreed upon before implementation.
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    2 High outdoor temperatures expose persons on the Worksite to the risk of dehydration. The
    Contractor will provide shaded rest areas, rest periods and drinking water supplies for all
    o

    persons on the Worksite.


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    et

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

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

    10.9.6 Additional Environmental Protection and Pollution Control

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

    2 The Contractor shall comply with all rules and regulations regarding environmental protection
    and pollution control issued by the MoE, and also where relevant, the predecessor to the
    MoE, the Supreme Council for the Environment and Natural Reserves.
    QCS 2014 Section 01: General Page 46
    Part 10: Occupational Health and Safety

    10.9.7 Plant and Equipment Test Certificates

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

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

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

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

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

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    (a) Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010

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    (b) Overhead Cranes: BS 466 and BS 5744
    (c) Slings: BS 1290
    (d) Chain Blocks: BS 3243
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    (e) Shackles: Alloy : BS 3551, High Tensile Steel : BS 3032
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    10.10 LABOUR ACCOMODATION


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    10.10.1 General
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    1 These specifications for workers' accommodation can be accepted for implementation as


    long as in the interest of the worker provided they do not disturb the labour accommodation
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    requirements of the decision of the Minister of Labour No. (17) for the year 2005 or any other
    matters developed in this context.
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    10.10.2 Quality of Labour Accommodation


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    et

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

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

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

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

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

    6 The Contractor shall designate pick up and drop off points (for buses) in such a way as to
    minimize walking distances for residents and to minimize noise and air quality impacts on
    residential buildings.
    QCS 2014 Section 01: General Page 47
    Part 10: Occupational Health and Safety

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

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

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

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

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    11 The Contractor shall be aware of any changes in law relating to the provision of temporary

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    labour accommodation.

    10.10.3 Provision for Fire Safety

    1 ta
    The Contractor shall provide for adequate fire-fighting equipment in the labour
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    accommodation (notwithstanding other local laws and regulations requiring same).
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    2 All relevant signage, notices, documentation and training relating to fire safety at labour
    accommodation shall be provided in appropriate languages, based on the demographics of
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    the facility.

    10.10.4 Provision for Health Care


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


    et

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

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

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

    5 The Contractor shall include a Public Health Training module as part of induction training for
    all new labour accommodation residents. As a minimum, this shall address:
    QCS 2014 Section 01: General Page 48
    Part 10: Occupational Health and Safety

    (a) Personal hygiene and the appropriate use of the sanitary facilities provided (flush
    toilets, showers, hand washing, waste disposal facilities etc.).
    (b) Awareness of communicable diseases (including Sexually Transmitted Diseases), their
    transmission and prevention.
    (c) Practical information regarding residents rights and means of access to on-site and
    off-site medical facilities.
    (d) Food safety.
    (e) Littering, safe disposal of waste and related community hygiene standards.

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

    (a) Signage in kitchens, bathrooms etc. promoting hygienic practices.

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    (b) Educational videos and presentations.

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    10.10.5 Access to Transport

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    1 The Contractor shall provide access to transport, free-of-charge to/from:

    (a)
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    Worksites, including backup services from worksite to labour accommodation for those
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    who failed to access scheduled services.
    (b) Availability nearby for community facilities, shops and recreation areas during leisure
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    time.
    (c) Religious facilities at suitable times.
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    (d) Off-site medical facilities, including emergency access at all times.


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    2 Transport services shall be scheduled in such a way as to minimise waiting times and
    maximise accessibility.
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    3 The Contractor shall use safe modes of transport only. The practice of transporting workers
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    in open-back trucks is forbidden.


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    10.10.6 Access to Religious, Social and Domestic Facilities


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

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

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

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

    5 The Contractor shall provide preferably on-site, open spaces (for sports and recreation).
    Where space constraints are such that this is impossible, readily accessible off-site spaces
    shall be provided.
    QCS 2014 Section 01: General Page 49
    Part 10: Occupational Health and Safety

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

    (a) Access to banking/money transfer services, including transportation to banking/money


    transfer facilities.
    (b) Laundry facilities.
    (c) Retail outlet(s) selling, as a minimum, essential items (e.g. food items, clothing,
    toiletries, phone cards, stamps etc.).
    (d) Communications.
    These services shall preferably be available on or within walking distance of the labour
    accommodation.

    10.10.7 Access to Communications

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    1 The Contractor shall provide a telephone, available at all times, for calling the emergency
    services. This facility shall be centrally located, conspicuous and all residents shall be aware

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    of this facility.

    2
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    The Contractor shall provide access nearby to the following:
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    (a) Retail outlet selling mobile phone credit.
    (b) Postal service, both inward and outbound.
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    (c) Facility for residents to receive emergency messages (e.g. in case of family
    emergency abroad).
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    10.10.8 Number, Quality and Location of Sanitation Facilities


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    1 The Contractor shall adhere to an appropriate standard for the provision of toilets and
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    showers etc. These facilities shall be maintained in good working order and shall be cleaned
    regularly.
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    2 The Contractor shall develop and implement a Waste Management Plan for the labour
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    accommodation. This plan shall address the collection, segregation, storage, transport (off-
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    site) and disposal (recycling) of wastes.


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

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

    10.10.9 Food Preparation Areas

    1 The Contractor shall adhere to relevant local regulations relating to food preparation facilities.
    In the absence of such local regulations, an appropriate regional standard shall be applied
    The Contractor shall provide adequate food preparation facilities to allow cultural sensitivities
    to be respected such as separate preparation areas for meat and vegetables, and
    appropriate labelling and handling of food products.
    QCS 2014 Section 01: General Page 50
    Part 10: Occupational Health and Safety

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

    10.10.10 Pest and Vermin Control

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

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

    10.10.11 Security at Labour Accommodation

    1 The Contractor shall provide adequate security personnel, based on the size, layout and
    population of labour accommodation.

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    2 The Contractor shall provide Protocols (Codes of Conduct) for the security personnel

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    operating at labour accommodation. These Protocols shall clearly define the nature and
    permitted magnitude of response to security incidents. They shall also set out the
    circumstances under which security incidents should be handed over to Police control.

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    Protocols will be developed in consultation with the Engineer
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    3 The Contractor shall ensure that all security personnel are adequately trained in the Protocols
    for security personnel.
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    4 The Contractor shall retain records of all security incidents arising at labour accommodation.
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    Such records shall include, as a minimum, the name, age and nationality of all those involved
    (including security personnel), and the nature of the incident. These records shall be made
    available to the Engineer.
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    5 The Contractor shall provide labour accommodation residents with secure facilities for the
    storage of personal items and valuables.
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    6 The Contractor shall manage the movement of goods and personnel onto the
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    accommodation facility.
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    7 The Contractor shall maintain adequate lighting on and around the labour accommodation at
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    all times, therefore making it safer for residents to move around at all times.

    10.10.12 Social Issues

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

    2 The Contractor shall include an Intercultural Understanding module as part of induction


    training for all new labour accommodation residents. This shall include:

    (a) Basic introduction to cultural norms and practices of other accommodation residents.
    (b) An explanation of native or local customs, festivals or religious rites.
    QCS 2014 Section 01: General Page 51
    Part 10: Occupational Health and Safety

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

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

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

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    10.10.13 Competence of Labour Accommodation Management

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    1 The Contractor shall provide Protocols (Codes of Conduct) for the labour accommodation
    management personnel. These Protocols shall clearly define the nature of issues and

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    incidents which are considered within the remit of labour accommodation management.
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    They shall also include guidelines outlining appropriate parties to whom incidents should be
    referred and at what stage. Protocols will be developed in consultation with the Engineer
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    2 The Contractor shall retain records of all issues and incidents, at labour accommodation,
    which are reported to or dealt with by labour accommodation management. Such records
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    shall include, as a minimum, the name, age and nationality of all those involved (including
    members of the accommodation management team), and the nature of the issue or incident.
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    These records shall be made available to the labour accommodation management company.
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    3 The Contractor shall ensure that no member of labour accommodation management accepts
    any form of payment by way of bribery or extortion or for any reason. Similarly the Contractor
    shall commit to permanently removing any member of labour accommodation management,
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    from the accommodation, if they are found to have accepted or demanded such payments.
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    In this event, the Contractor shall report any such offences to the appropriate local authorities
    et

    to determine if a criminal offence has been committed.


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

    10.10.14 Environmental Conditions at Labour Accommodation

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

    2 Where labour accommodation is to be sited on or close to work sites/industrial sites, the


    accommodation facilities shall be located up-wind (based on prevailing wind) of the site and
    the distance between the camp and air discharge points around the site shall be maximised.
    Noise levels shall not exceed the requirements for night time hours residential areas, as
    outlined in local laws and regulations.
    QCS 2014 Section 01: General Page 52
    Part 10: Occupational Health and Safety

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

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

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

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

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    7 Roads and parking areas shall be paved, or where this is impractical, dust suppression

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    techniques shall be used to keep dust levels down within labour accommodation.

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

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    10.10.15 Health and Safety for Labour Accommodation Residents
    qa
    1 The Contractor shall extend Workmens Compensation and Employers Liability Insurance to
    as

    cover their staff while resident in labour accommodation.

    2 The Contractor shall extend the accident reporting requirements, to include accidents
    se

    occurring at off-site labour accommodation directly associated with the Project.


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    END OF PART
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    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    11 ENGINEERS SITE FACILITIES .............................................................................. 2


    11.1 GENERAL ............................................................................................................... 2
    11.1.1 Scope 2
    11.2 ENGINEERS SITE OFFICES ................................................................................. 2
    11.2.1 General 2
    11.2.2 Type 1 Offices 2
    11.2.3 Type 2 Offices 3
    11.2.4 Car Parking Facilities 6
    11.3 UTILITY CONNECTIONS ........................................................................................ 6
    11.3.1 General 6
    11.3.2 Electricity 6
    11.3.3 Water 6

    .
    11.3.4 Telephone 7

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    11.3.5 Internet 7

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    11.4 PROVISION OF EQUIPMENT AND SUPPLIES ...................................................... 7
    11.4.1 General 7
    11.4.2
    11.4.3
    Computers and Scanners/Printers
    Photocopier ta 7
    8
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    11.4.4 Measuring and Recording Equipment 9
    11.4.5 Stationary Supplies 9
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    11.4.6 Safety Equipment and Clothing 10


    11.4.7 Telephones and Facsimile Machines 10
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    11.5 ATTENDANCE ...................................................................................................... 11


    11.5.1 Assistance to the Engineer 11
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    11.5.2 Contract Administration 11


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    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    11 ENGINEERS SITE FACILITIES


    11.1 GENERAL

    11.1.1 Scope

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

    2 Related Sections and Parts are as follows


    This Section Part 10 Occupational Health and Safety
    Part 13 Setting Out of the Works

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    11.2 ENGINEERS SITE OFFICES

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    11.2.1 General

    1 The Contractor shall provide site offices the type and number as stated in the Project
    ta
    Documentation. The position of the site offices shall be to the approval of the Engineer.
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    2 Upon removal of the site offices, the area occupied or otherwise affected by them shall be
    reinstated to its original condition.
    as

    11.2.2 Type 1 Offices


    se

    1 Unless described elsewhere in the Project Documentation the Contractor shall provide,
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    maintain and remove on completion of the Works the Engineers site offices described in this
    Clause.
    ov

    2 The Contractor shall proceed with the provision of a site office for the exclusive use of the
    Engineer immediately following the award of the Contract and shall provide temporary
    o

    alternative accommodation to the Engineers approval until such time as the office is made
    it

    available.
    et

    2
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    3 The office shall have a minimum area of 20 m and shall comply with the following:

    (a) The structure shall be weatherproof.


    (b) The windows and doors shall be dust-proof and the windows shall be fitted with fly
    screens.
    (c) The office shall be air-conditioned to maintain a maximum steady dry bulb temperature
    of 25C at a relative humidity of 50% under the expected climatic conditions expected
    at the Site.
    (d) Adequate effective lighting and power outlets shall be installed in accordance with the
    latest requirements of the Qatar General Electricity & Water Corporation.
    (e) The walls and ceilings shall be painted with emulsion paint.

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

    (a) 1 No. kneehole pattern desk with a total of six lockable drawers, approximately 1500 x
    800 x 760 mm in size.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    (b) 1 No. swivel chair with armrests.


    (c) 2 No. stacking or folding chairs.
    (d) 1 No. hanging file or plan chest suitable for AO size prints.
    (e) 1 No. wastepaper basket.
    (f) 1 No. two drawer filing cabinet.
    (g) 1 No. wall mounted pin board, 1000 x 2000 mm in size.

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

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

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    7 The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled

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    drinking water for the consumption of the Engineer.

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

    11.2.3 Type 2 Offices


    ta
    qa
    1 The Engineers site offices described in this Clause shall be provided in lieu of Type 1 Offices
    only where it is a stated requirement of the Project Documentation.
    as

    2 The offices shall be portable units, mounted on skids or similar and where directed in the
    se

    Project Documentation shall become the property of the Government on completion of the
    Contract. On completion of the Contract, the offices which are to become the property of the
    er

    Government shall be repaired and redecorated to the satisfaction of the Engineer; they shall
    then delivered to a location designated by the Engineer within 50 km of the Site.
    ov

    3 The buildings shall conform to the general configuration shown below. The number of each
    type of unit shall be as stated in the Project Documentation.
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    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

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    ta
    qa
    as

    4 The Contractor shall proceed with the provision of the portable offices, which shall be for the
    se

    exclusive use of the Engineer immediately following the award of the Contract and shall
    provide temporary alternative accommodation to the Engineers approval until such time as
    er

    the offices are made available.


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    5 The Contractor shall submit to the Engineer for approval a comprehensive specification and
    drawings showing the accommodation proposed complete with furnishings, equipment and
    o

    fittings before placing any orders.


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

    7 The units may be constructed of composite timber framed panels with wood or metal
    cladding, any combination of these, or alternative forms or construction which comply with
    the following levels of performance:
    2
    Walls Thermal conductance - 0.60 w/m C
    Fire resistance - hour

    2
    Roof Thermal conductance - 0.60 m C
    Roof resistance - hour
    8 Roof coverings shall be selected for durability, freedom from excessive maintenance, and the
    ability to withstand extreme exposure to sun, heat and humidity.

    9 The units shall be finished internally and externally with low maintenance materials.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

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

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

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

    (a) 1 No. kneehole pattern desk with a total of six lockable drawers and
    approximately 1500 x 800 x 760 mm in size.
    (b) 1 No. swivel chair with armrests.

    .
    (c) No. stacking or folding chairs.

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

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    (e) 1 No. wastepaper basket.
    (f) 1 No. two drawer filing cabinet.
    (g) ta
    1 No. wall mounted pin board, 1000 x 2000 mm in size.
    qa
    13 Each toilet shall be provided with the following sanitary fittings to the approval of the Engineer
    and an adequate supply of hot and cold water at all times:
    as

    (a) 1 No. low level WC suite.


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    (b) 1 No. Wash-hand basin.


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    (c) 1 No. shower tray, mixer fittings, rose and shower curtain.
    (d) 1 No. toilet roll holder, towel rail, soap dish and mirror.
    ov

    (e) a suitable number of cups, saucers and drinking glasses.


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    14 The samples and meeting room shall be provided with the following furniture to the approval
    it

    of the Engineer:
    et

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


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    (b) No. folding or stacking chairs.


    (c) 1 No. wall mounted blackboard, 1000 x 2000 mm in size.
    (d) 1 No. wall mounted pin board, 1000 x 3000 mm in size.
    (e) 1 No. shelf unit for approved samples with 5 tiers of shelves 400 mm wide x 2400 mm
    long overall.

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

    16 The Kitchen shall be provided with the following equipment to the approval of the Engineer

    (a) 1 No. stainless steel single bowl single drainer sink with hot and cold water and
    cupboards underneath
    (b) 1 No. floor mounted two door cupboards to match sink.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    (c) Cabinets and shelves to match sink, as required.


    (d) 2 ring cooker and microwave.
    (e) 1 No. Refrigerator/Freezer with a capacity no less than 500 litres.
    (f) 1 No. three pint kettle and sufficient crockery and cutlery.
    (g) A suitable number of mugs, cups, saucers and drinking glasses.
    (h) Table coasters for use on desk tops.
    (i) Hand towels and drying up cloths, laundered regularly.
    (j) Dishwashing facilities, clothes, sponges and washing up liquid, all replaceable.
    (k) Cleaning brushes, mop, bucket and floor clothes.

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

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

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

    20 ta
    Each type of unit shall be provided with fire extinguishers and water cooler.
    qa
    11.2.4 Car Parking Facilities
    as

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

    2 The number of shaded car parking spaces required shall be 2 No. for Type 1 Offices and 6
    er

    No. for Type 2 Offices unless otherwise stated in the Project Documentation.
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    11.3 UTILITY CONNECTIONS


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    11.3.1 General
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    et

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

    Clause.

    11.3.2 Electricity

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

    11.3.3 Water

    1 The Contractor shall arranged for the provision of an uninterrupted water supply to the
    Engineers offices during all working hours and at any other time as requested by the
    Engineer for the duration of the Contract.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

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

    11.3.4 Telephone

    1 The Contractor shall arrange for the provision of two (2) land lines for the sole use of the
    Engineer for Type 1 Offices and three (3) land lines for the sole use of the Engineer for Type
    2 Offices.

    2 The Contractor may recover the net cost of international calls made by the Engineer.

    11.3.5 Internet

    1 .The Contractor shall arrange for the provision of a dedicated and uninterrupted internet

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    access to the Engineers offices during all working hours and at any other time as requested

    .l.
    by the Engineer for the duration of the Contract. The internet connection should be provided

    rw
    with a bandwidth running at a minimum of 1 mbps upload capacity.

    11.4 PROVISION OF EQUIPMENT AND SUPPLIES


    ta
    qa
    11.4.1 General

    1 The following items of equipment, supplies and associated level of service shall all be
    as

    provided unless detailed elsewhere in the Contract Documentation.


    se

    11.4.2 Computers and Scanners/Printers


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    1 The Contractor shall provide new network/internet capable computers and scanners/printers
    for the sole use of the Engineer. The number of computers and scanners/printers required
    ov

    and their performance specification shall be as detailed in the Project Documentation. The
    Contractor shall also supply and install any computer software as detailed in the Project
    Documentation.
    it o

    2 The Contractor shall maintain the computers and scanners/printer for the duration of the
    et

    Contract and provide all consumables necessary for its operation.


    m

    3 The Contractor shall be responsible for installing legal copies of operating system and
    software, trouble shooting, supplying of required consumables and maintenance of the
    system.

    4 Operating system and software requirements shall be as specified by the Engineer, with the
    following as a minimum:

    (a) Latest version of Microsoft Windows Operating System


    (b) Latest version of Microsoft Office

    5 All software must be of latest version and Arabic enabled, to the approval of the Engineer.

    6 The Contractor shall ensure that all computers and scanners/printers provided for the
    Engineers use are networked within the Engineers facilities to the satisfaction of the
    Engineer.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    7 The Contactor shall provide new desktop computers and laptops as shown in the Schedule
    of Rates minimum 20-inch Flat Panel VGA/analogue colour monitors for use by the Engineer.

    8 The Desktop and laptop computers shall comply with the following:

    (a) Intel Core 2 Duo Processor (1.86GHz,1066MHz,2MB cache)


    (b) 1000GB(7200rpm)Serial ATA Hard Drive
    (c) 56k Modem
    (d) 32X DVD+/-RW Drive
    (e) Wireless network adaptor (Wi-Fi)
    (f) Wireless Keyboard & Mouse
    (g) Card Reader

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    9 The Desktop and laptop computers shall comply with the following: New licensed copies of
    MS Windows, MS Office Professional, MS Project and AUTOCAD, Primavera P6 and

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    Primavera Contract Manager (PCM) SOFTWARE SHALL BE PROVIDED.

    10 Colour printer shall be of the laser type suitable for A3 size paper and having scanning and
    ta
    copying facilities built in. It shall be quiet in operation (Hewlett Packard Desk Jet (latest
    qa
    model) or similar).

    11 The Computer equipment shall be returned to the Contractor at the end of Maintenance
    as

    Period. The Contractor shall be responsible for supply of all necessary cartridges and paper
    and for maintenance of the equipment by the manufactures agent throughout the period of
    se

    the Work order.


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    12 The Contractor shall provide all necessary voltage stabilization equipment to ensure trouble-
    free operation of the computer equipment.
    ov

    13 All computers and printers shall be networked.


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    11.4.3 Photocopier
    it
    et

    1 The Contractor shall provide a new photocopier for the sole use of the Engineer. The
    m

    performance specification for the photocopier shall be as detailed in the Project


    Documentation.

    2 The Contractor shall maintain the photocopier for the duration of the Contract and provide all
    consumables necessary for its operation.

    3 Contractors shall provide a new floor standing, stationary platen, and plain paper colour
    photocopier for use and approved by the Engineer.

    4 The photocopier shall be provided with an automatic document feeder capable of copying
    both sides.

    5 The Range of copy sizes of the photocopier shall be from A3 size (297420mm) to A4 size
    (210297mm), portrait and landscape. Three paper storage trays shall be provided.

    6 The photocopier shall be capable of reducing/enlarging originals by 50% to 200% in 1%


    increments.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    7 The photocopier shall have an A4 size rotating paper cassette and automatic paper
    size/zoom ratio selection.

    8 Throughput shall be not lesson than 40 A4 copies per minute.

    9 The photocopier shall be able to scan and email documents.

    10 The photocopier shall be returned to the contractor at the end of period of Maintenance. The
    contractor shall be responsible for supplying the necessary paper and maintenance of the
    equipment by the manufactures agent throughout the work order.

    11.4.4 Measuring and Recording Equipment

    1 The Contractor shall provide measuring and recording equipment for the sole use of the
    Engineer. The following items, which shall be to the approval of the Engineer, shall be

    l .
    provided for the duration of the Contract:

    .l.
    (a) 1 No. Electronic Distance Measurement (EDM) station.

    rw
    (b) 1 No. 1 Total Station theodolite (or equivalent) including all necessary tripods, prisms
    etc.
    (c) ta
    1 No. Automatic engineers level including tripod.
    qa
    (d) 1 No. Metric levelling staff.
    (e) 1 No. Calibrated steel survey band 50m long.
    as

    (f) 2 No. 30m nylon tapes.


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    (g) 2 No. 25 m metal tapes.


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    (h) 4 No. 5m pocket tapes.


    (i) 6 No. Ranging rods.
    ov

    (j) 1 No. Masons Spirit level.


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    (k) 1 No. Bitmac thermometer.


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    (l) 1 No. digital camera.


    et

    (m) Level and field books as required.


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    2 Other equipment such as pegs, tools, etc, which are necessary for the checking of the Works
    shall be provided as requested by the Engineer.

    3 The Contractor shall maintain and replace as necessary the equipment for the duration of the
    Contract. Surveying instruments shall be new or in as good as new condition, of an approved
    make with a current certificate of adjustment.

    11.4.5 Stationary Supplies

    1 The Contractor shall supply stationary for the Engineer for the duration of the Contract.
    Stationary items shall include, but not necessarily be limited to, the following:

    (a) Files and file dividers (A4 and A3 size).


    (b) Paper (A4 and A3 size).
    (c) Writing pens, marker pens, highlighter pens (various colours).
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    (d) Pencils (various colours).


    (e) Pencil sharpeners.
    (f) Erasers.
    (g) Staplers and staples.
    (h) Hole punches.
    (i) Paper chips and bull dog clips.

    11.4.6 Safety Equipment and Clothing

    1 The Contractor shall supply safety equipment and clothing for the Engineer and his staff.
    Safety equipment and clothing shall include, but not necessarily be limited to, the following:

    (a) Safety helmets, boots, gloves, High visibility vests, safety glasses (Clear and tinted)

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    (b) Safety belts and harnesses.

    rw
    (c) Boiler suits.
    (d) Any other PPE identified by the Contractors job hazard analysis or risk assessment
    process
    ta
    qa
    2 The Contractor shall also supply gas detection equipment and breathing apparatus in
    accordance with the relevant provisions of Part 10 of this Section, Occupational Health and
    Safety.
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    11.4.7 Telephones and Facsimile Machines


    se

    1 For Type 1 Offices, the Contractor shall supply and install a telephone and facsimile
    er

    machine. The telephone and facsimile machine should conform to the relevant provisions of
    any Telecom Provider standard or requirement.
    ov

    2 For Type 2 Offices, the Contractor shall supply and install a telephone in each office and the
    meeting room. Each telephone shall be connected to a private address box exchange
    o

    (PABX) system. The Contractor shall also supply and install a facsimile machine. The
    it

    telephones, PABX system and facsimile shall conform to the relevant provisions of any
    et

    Telecom Provider standard or requirement.


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    3 The Contractor shall provide a new A4 size plain paper desktop facsimile machine complying
    with the following:

    (a) 2 Line 24 character LCD Display


    (b) ITU compatible
    (c) Resolution horizontal scanning 8 pixel/mm
    (d) Vertical scanning Standard 3.85 lines/mm
    (e) Fine 7.7 lines/mm
    (f) 150 sheet paper tray (80g/m2

    4 The facsimile machine shall be returned to the contractor at the end of maintenance period.
    The Contractor shall be responsible for supply of all necessary toner or ink cartridges and
    plain white paper and for maintenance of the equipment by the manufactures s agent
    throughout the Work order.
    QCS 2014 Section 01: General
    Part 11: Engineers Site Facilities

    5 The Contractor shall provide six digital cameras and one digital video camera for the
    exclusive use of the Engineer or his designated representative and supply software,
    batteries, cables and USB flash drives or external hard drives as required. The Digital
    camera shall have a minimum specification of 35-105 zoom, with a minimum of 16.0
    megapixels for prints up to 2030, 8GB internal memory and video/audio facility. The
    cameras shall be returned to the contractor at the end of the contract period

    11.5 ATTENDANCE

    11.5.1 Assistance to the Engineer

    1 The Contractor shall provide every assistance to the Engineer in carrying out his duties.

    2 The Contractor shall provide for the use of the Engineers Representative and his staff, any
    chainman/assistants to carry out any duties whatsoever, as required by the Engineers

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    Representative.

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    11.5.2 Contract Administration

    1 The Contractor shall provide secretaries, cleaners and tea persons for the exclusive use of
    the Engineer for the duration of the Contract.
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    END OF PART
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    QCS 2014 Section 01: General Page 1
    Part 12: Contractors Site Facilities

    12 CONTRACTORS SITE FACILITIES GENERAL ........................................... 2

    12.1 GENERAL ...................................................................................................... 2


    12.1.1 Scope 2
    12.1.2 References 2
    12.2 CONTRACTORS SITE FACILITIES ............................................................. 2
    12.2.1 Buildings 2
    12.2.2 Site Fabrication Areas 2
    12.2.3 Materials Storage Area 2
    12.2.4 Power, Water, Lighting and Heating 3
    12.2.5 Miscellaneous 3
    12.3 PROJECT SIGN BOARD............................................................................... 3

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    12.3.1 Project Sign Board 3

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    12.4 ADVERTISING .............................................................................................. 4
    12.4.1 Photographs 4
    12.4.2 Name Boards and Other Advertising
    ta 4
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    12.5 PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE
    STATION ....................................................................................................... 4
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    12.5.1 General 4
    12.5.2 Requirements 4
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    QCS 2014 Section 01: General Page 2
    Part 12: Contractors Site Facilities

    12 CONTRACTORS SITE FACILITIES GENERAL

    12.1 GENERAL

    12.1.1 Scope

    1 This Part specifies the requirements for the Contractors temporary site facilities.

    12.1.2 References

    1 Related Sections and Parts are as follows:

    This Section Part 9 Materials.

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    12.2 CONTRACTORS SITE FACILITIES

    .l.
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    12.2.1 Buildings

    1 The Contractor shall provide all offices, sheds, stores and other buildings necessary for him
    ta
    to undertake all duties, obligations and activities associated with the construction of the
    qa
    Works.

    2 All buildings shall be supplied and maintained in good condition and shall be of neat
    as

    appearance.
    se

    3 The position of all the Contractors temporary site buildings shall be to the approval of the
    Engineer.
    er

    4 The Contractor shall maintain an office at the Site for the duration of the Contract. This office
    ov

    shall be open at all times during Site working hours.

    5 Upon completion of the Contract, all temporary site buildings shall be removed and the area
    o

    occupied or otherwise affected by them reinstated to its original condition.


    it
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    6 The Government of Qatar will grant a right of access only within the road reservation. Should
    m

    the Contractor need to use adjacent areas of land for camps, plant site etc, he shall arrange
    for the right to use the said land himself.

    7 This clause in no way invalidates the obligations of the General Conditions of Contract.

    12.2.2 Site Fabrication Areas

    1 The Contractor shall provide an area suitable for assembly and fabrication purposes.

    2 Fabrication areas shall simulate factory conditions if required in the Project Documentation.

    12.2.3 Materials Storage Area

    1 The Contractor shall provide sufficient and appropriate materials storage areas. The storage
    areas shall be suitable for the materials to be stored in them and shall offer necessary
    protection where required.
    QCS 2014 Section 01: General Page 3
    Part 12: Contractors Site Facilities

    2 The Contractor shall ensure that the storage areas comply with the relevant provisions of
    Part 9 of this Section, Materials.

    12.2.4 Power, Water, Lighting and Heating

    1 The Contractor shall provide, maintain and subsequently remove temporary services for
    power supply, water supply, lighting and heating.

    2 All electrical installations shall be in the charge of a competent person who shall accept full
    responsibility for its use and any alterations or additions thereto. The name, designation and
    telephone number of such person shall be prominently displayed close to the main switch or
    circuit breaker of the installation, and also in the Contractors site office.

    3 Site work power tool supplies (except for operation of pumps) shall be of 110 volts (55 volts
    to earth). All electricity supply cables shall be buried or properly supported and protected and

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    shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools

    .l.
    and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used.

    rw
    4 All site electrical installations shall comply with the requirements of the current regulations of
    QGEWC.

    12.2.5 Miscellaneous ta
    qa
    1 The Contractor shall provide, maintain and subsequently remove temporary roads, paths,
    as

    parking areas and refuse disposal areas. The area occupied by temporary roads, paths,
    parking areas and refuse disposal areas or otherwise affected by them shall be restored to
    se

    their original condition on completion of the Contract.


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    12.3 PROJECT SIGN BOARD


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    12.3.1 Project Sign Board

    1 Standard Signboard: The Contractor shall provide and erect a temporary signboard at the
    o

    location of his approved site compound. In addition he shall provide signboards at the start
    it

    and end of each ongoing work location for all works whether major or minor.
    et
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    2 Project Identification Signboard: Information signboards shall be clearly displayed on


    approaches to works in the highway at each ongoing work location for all works whether
    major or minor. These shall be provided by the Contractor and shall be positioned so as not
    to cause hindrance to the movement of vehicular or pedestrian traffic. The signs shall be
    mounted on sturdy metal frames, be mobile and reusable, and shall be illuminated at night.

    3 The Project sign boards shall comply with the standard details, as updated by the project
    drawings and specifications, and shall be to the approval of the Engineer. In addition, the
    Contractor shall obtain all necessary approvals from the relevant authorities prior to erection.
    The Contractor shall be responsible for the structural stability of the signboards but shall
    submit details of his proposals for support to the Engineer for approval.

    4 The Contractor shall maintain, move and adapt the signboards as required during the
    progress of the Works and shall remove them upon completion.
    QCS 2014 Section 01: General Page 4
    Part 12: Contractors Site Facilities

    12.4 ADVERTISING

    12.4.1 Photographs

    1 The Contractor shall not use photographs or any details of his work in connection with the
    Contract in any form of publicity or advertisement in any part of the world without having first
    obtained the Engineers approval to its content and context.

    12.4.2 Name Boards and Other Advertising

    1 Details of any further sign boards other than as designed in Clause 12.3.1 or advertisements
    that the Contractor may wish to erect on site shall be to the approval of the Engineer.

    12.5 PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE

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    STATION

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    12.5.1 General

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    1 Ambulance Spoke Station is a temporary structure. This can be relocated quickly to any

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    location in a rapidly changing infrastructure, which is a vital component of the design. It is
    designed to provide covered parking for up to two ambulances and accommodation for a
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    small crew room for up to four paramedics. The crew need shelter from the summer heat in a
    safe environment in a prime response location to be ready for emergency calls. The stations
    are versatile and designed to be completely self-contained. It doesn't require to be connected
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    to Electricity, Water or Sewerage or require any physical links to service providers. All of its
    power is provided by solar panels. The cabin can be dismantled and moved to another site
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    within 48 hours, enabling Hamad Medical Corporation to relocate these small stations. The
    station does not require any form of building foundations, just level ground. Depending on the
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    location, some stations may require minor works for access to and from the road.
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    2 The contractor will in no way be relieved of his responsibility under Qatari law to provide
    medical care, facilities, insurance, etc. to workers on site, and that Hamad Medical
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    Corporations facility is mainly for the purpose of the general public (so that Hamad Medical
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    Corporation can respond more quickly to emergency incidents in a rapidly changing


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    infrastructure)
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    12.5.2 Requirements

    1 If instructed by the Engineer, the Contractor shall make provision within or adjacent his site
    facilities for an Ambulance Spoke Station.

    2 The Contractor is only required to provide an area for the for the facilities. The Ambulance
    Spoke Station and vehicles will be provided and installed by Hamad Medical Corporation or
    an entity on their behalf.

    3 The area shall be a minimum of 10 metres by 17 metres.

    4 The area must be levelled as the surrounding area of the Contractor facilities.

    5 The areas shall be provided with clear access to the road network.

    6 Access to the Ambulance Spoke Station is required 24hours/day 7 days/week.


    QCS 2014 Section 01: General Page 5
    Part 12: Contractors Site Facilities

    7 Ambulance vehicle access is required to at least one long side.

    8 Access for maintenance (water resupply, cleaning, removal of waste etc.) is required to one
    short side.

    9 The allocated area shall be approved in writing by the Engineer after consultation with
    Hamad Medical Corporation.

    END OF PART

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    QCS 2014 Section 01: General Page 1
    Part 13: Setting Out of the Works

    13 SETTING OUT OF THE WORKS .................................................................. 2


    13.1 GENERAL ...................................................................................................... 2
    13.1.1 Scope 2
    13.2 SITE INFORMATION AND INSPECTION ..................................................... 2
    13.2.1 Site Information 2
    13.2.2 Site Inspection 2
    13.3 LEVELS AND REFERENCE GRID ................................................................ 2
    13.3.1 Temporary Bench Marks 2
    13.3.2 Site Grid 3
    13.4 SURVEYING .................................................................................................. 3
    13.4.1 Site Survey 3

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    13.5 SETTING OUT ............................................................................................... 3

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    13.5.1 Setting Out of the Works 3

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    13.5.2 Setting Out of Works Sited on Private Land 4

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    QCS 2014 Section 01: General Page 2
    Part 13: Setting Out of the Works

    13 SETTING OUT OF THE WORKS


    13.1 GENERAL

    13.1.1 Scope

    1 This Part specifies the requirements for setting out of the Works and includes locating
    existing services, surveying the Site and establishment of temporary bench marks.

    2 The Engineer reserves the right to order levels to be taken at any time considered necessary
    for the full and proper supervision and measurement of the Works.

    3 Related Sections and Parts are as follows:


    Engineers Site facilities.

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    This Section Part 11

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    13.2 SITE INFORMATION AND INSPECTION

    13.2.1 Site Information


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    1 Before commencing the setting out of the Works the Contractor shall ascertain the location of
    all existing underground services within the Site boundary. The Contractor shall prepare a
    plan detailing the location of the services.
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    2 Any conflict between existing services and any part of the proposed Works shall be brought
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    to the attention to the Engineer without delay.


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    3 Any re-work resulting from the Contractors failure to locate and identify services shall be
    undertaken at the Contractors cost.
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    13.2.2 Site Inspection


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    1 Before commencing the setting out of the Works, the Contractor and the Engineer shall
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    make an inspection of the Site.


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    2 Where appropriate, the Engineer shall require the Contractor to arrange for surveys to be
    undertaken, in conjunction with the owners or occupiers, of the condition of roads, properties,
    lands and crops which may be affected by the Works. Before any work affecting such roads,
    properties, lands or crops is commenced, the Contractor shall confirm in writing to the
    Engineer that the relevant survey is a true and accurate record of their condition.

    13.3 LEVELS AND REFERENCE GRID

    13.3.1 Temporary Bench Marks

    1 . The Contractor shall establish accurate temporary bench marks on permanent blocks from
    which the levels to which the Works are to be constructed may be transferred. The location
    of temporary bench marks shall be agreed with the Engineer. The level of temporary bench
    marks shall be related to the Qatar National Height Datum.

    2 The Contractor shall prepare a plan detailing the location of the bench marks and temporary
    bench marks and keep it up to date for the duration of the Contract.
    QCS 2014 Section 01: General Page 3
    Part 13: Setting Out of the Works

    3 The Contractor shall protect and maintain the temporary bench marks until the Works are
    complete. Upon completion of the Works the Contractor shall clear away the temporary
    bench marks to the satisfaction of the Engineer.

    4 The Contractor is responsible for checking the accuracy of temporary bench mark. Any re-
    work resulting from incorrect or inaccurate temporary bench marks shall be undertaken at the
    Contractors cost.

    13.3.2 Site Grid

    1 When it is a requirement of the Project Documentation, or unless otherwise notified by the


    Engineer, the Contractor shall establish a Site Grid. The orientation of the Site Grid shall be
    determined by the layout of the proposed works and as agreed with by the Engineer. Grid
    spacing shall be 20m in each direction unless otherwise notified by the Engineer. Grid
    notation shall be numerical in one direction (y-axis) and alphabetic in the other (x-axis).

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    2 The grid shall be tied to the Qatar National Grid. An existing control station related to the

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    Qatar National grid will be indicated by the Engineer for this purpose.

    13.4 SURVEYING
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    13.4.1 Site Survey

    1 The Contractor shall provide the Site survey and the correctness of that survey shall be
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    entirely the Contractors responsibility.


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    2 The Site survey shall comply with the requirements of the Qatar Survey Manual as a
    minimum.
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    3 The Contractor shall, within 3 weeks of the date of commencement of the Works, carry out a
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    check of the co-ordinates and levels of all permanent monuments, bench marks and survey
    markers used in the determination of the site survey model and proposed to be used for the
    setting out of the Works.
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    13.5 SETTING OUT


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    13.5.1 Setting Out of the Works

    1 The Contractor shall carry out at his own cost the setting out of the Works.

    2 The Contractor shall be responsible for:

    (a) True and proper settings out of the Works in relation to reference data given
    in the Project Documentation.
    (b) Accurately setting out the positions, levels and dimensions of all parts of the Works.

    3 Any delay or loss resulting from errors in the setting out of the Works shall be the
    responsibility of the Contractor. Setting out shall be reviewed by the Engineer before
    commencing the Works, but such approval shall in no way relieve the Contractor of his
    responsibility for the correct execution of the Work.
    QCS 2014 Section 01: General Page 4
    Part 13: Setting Out of the Works

    4 The Contractor shall provide measuring and recording equipment for the Engineer in
    accordance with the relevant provisions of Part 11 of this Section, Engineers Site Facilities.
    The Contractor shall maintain all measuring and recording equipment in good working order
    at all times.

    5 The Contractor shall provide all assistance which the Engineer may require for checking the
    setting out and taking measurements of the Works, including labour, equipment and
    transportation.

    13.5.2 Setting Out of Works Sited on Private Land

    1 The Contractor shall notify the Engineer in writing fourteen (14) days in advance of his
    intention to set out any of part of the Works that lies in private land.

    2 The Contractor shall ensure that all requirements and instructions of private land owners are

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    strictly adhered to.

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    END OF PART

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    QCS 2014 Section 01: General Page 1
    Part 14: Temporary Works and Equipment

    14 TEMPORARY WORKS AND EQUIPMENT ............................................................. 2


    14.1 GENERAL ............................................................................................................... 2
    14.1.1 Scope 2
    14.2 TEMPORARY WORKS ........................................................................................... 2
    14.2.1 General 2
    14.3 TEMPORARY EQUIPMENT .................................................................................... 2
    14.3.1 General 2
    14.4 TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE ............................... 3
    14.4.1 General 3

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    QCS 2014 Section 01: General Page 2
    Part 14: Temporary Works and Equipment

    14 TEMPORARY WORKS AND EQUIPMENT


    14.1 GENERAL

    14.1.1 Scope

    1 This Part specifies the requirements for Temporary Works required in connection with
    construction of the Works and temporary plant and equipment required in connection with
    aiding the construction of the Works. It does not include overpumping activities in respect of
    sewers and drains.

    2 Related Parts and Sections are as follows:


    Section 2 Quality Assurance and Quality Control

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    Section 11 Health and Safety

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    3 Occupational Health and Safety concerning temporary works and equipment is covered in
    Section 11 Health and Safety

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    Quality Controlling temporary works and equipments is covered in Section 2 Quality
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    Assurance and Quality Control

    14.2 TEMPORARY WORKS


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    14.2.1 General
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    1 Everything used for and in connection with the Temporary Works shall be fit for the purpose,
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    in serviceable condition and in compliance with any relevant standard.


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    2 The Contractor shall design his Temporary Works to be of adequate strength, stability and
    suitability.
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    3 The Contractor shall submit details of any Temporary Works proposed to the Engineer for
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    review before commencing the work. Such details shall include, but not be limited to design
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    calculations and drawings. The submission to the Engineer of any such details shall not
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    relieve the Contractor of his responsibility for sufficiency of the Temporary Works or of his
    other duties and responsibilities under the Contract.

    4 The Contractor is responsible for ensuring that Temporary Works are not in any way
    detrimental to existing structures in any way. Particular care shall be taken with scaffolding to
    avoid staining or mechanical damage to finishing.

    5 The Contractor shall make safe and reinstate all areas affected by Temporary Works.

    14.3 TEMPORARY EQUIPMENT

    14.3.1 General

    1 The Contractor shall provide and maintain in good condition on the Site all plant, tools and
    vehicles necessary for the proper and safe execution of the Works.

    2 Temporary equipment shall be fit for the purpose for which it is to be used.
    QCS 2014 Section 01: General Page 3
    Part 14: Temporary Works and Equipment

    3 Temporary equipment shall only be operated by personnel who are trained and qualified.

    14.4 TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE

    14.4.1 General

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

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

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

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

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    the Engineer.

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    5 The following Standards and Code of Practice shall be complied with and where such
    documents are replaced or superseded the Contractor shall comply with the latest version:

    (a)
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    Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010.
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    (b) Overhead Cranes: BS 466 and BS 5744.
    (c) Slings: BS 1290, BS EN 1492, ISO 4309 / 3481 Pt 2, ASME B30.9.
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    (d) Chain Blocks: BS 3243.


    (e) Shackles: Alloy: BS 3551/ BS 6994.
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    (f) Chain: BS 4942 part 1 & 6.


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    (g) Hooks: BS 2903, ASME B30.10.


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    (h) Ring and link: BS 2902.

    6 A monthly inspection of lifting appliances shall be carried out by a competent person


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    employed by the Contractor. Full records of all such inspections and tests shall be kept by the
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    Contractor in an approved form and shall be made available to the Engineer immediately
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    upon demand. Copies of monthly inspection reports shall be submitted to the Engineer.
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    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 15: Temporary Controls

    15 TEMPORARY CONTROLS ..................................................................................... 2


    15.1 GENERAL ............................................................................................................... 2
    15.1.1 Scope 2
    15.2 TEMPORARY CONTROLS ..................................................................................... 2
    15.2.1 Construction Cleaning 2
    15.2.2 Dust Control 2
    15.2.3 Noise 2
    15.2.4 Nuisance and Trespass 2
    15.2.5 Pollution Control 3
    15.2.6 Surface Water and Groundwater Control 3
    15.2.7 Environmental protection 4

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    QCS 2014 Section 01: General Page 2
    Part 15: Temporary Controls

    15 TEMPORARY CONTROLS
    15.1 GENERAL

    15.1.1 Scope

    1 This Part specifies the Contractors responsibilities with respect to temporary controls needed
    to protect the Works and the environment.

    2 Related Sections and Parts are as follows:


    This Section Part 5 Interference

    15.2 TEMPORARY CONTROLS

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    15.2.1 Construction Cleaning

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    1 The Contractor shall be responsible for the proper upkeep and maintenance of the Site and
    Works and shall remove from the Site all rubbish and other waste as it accumulates.
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    Materials and equipment shall be positioned, stored and stacked in an orderly manner.
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    2 Properly constructed rubbish chutes shall be used for clearing the debris from upper floors.
    Debris shall be accumulated in suitable pre-determined areas and removed from the Site as
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    often as is practical.
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    3 On completion of the Works, any protective tape and other temporary coverings shall be
    removed and the internal and external surface of the structure shall be thoroughly cleaned to
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    completely remove all dust, dirt, stains, handmarks, paint spots, plaster, mortar droppings
    and other blemishes.
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    15.2.2 Dust Control


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    1 The Contractor shall conduct his operations and activities in such a manner that no operation
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    shall be included which will emit into the atmosphere any flying dust or dirt which might
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    constitute a nuisance.
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    15.2.3 Noise

    1 The Contractor shall restrict the use of plant, machinery, equipment and work practises likely
    to produce unacceptable noise levels to normal working hours.

    15.2.4 Nuisance and Trespass

    1 All reasonable means shall be used to avoid inconveniencing owners and occupiers of
    adjacent properties. All plant, machinery or equipment shall be placed and used on the Site
    so as to avoid any nuisance or trespass on adjoining property.

    2 Should it be necessary for any plant, machinery or equipment to project or operate over
    adjoining property, the Contractor shall obtain the permission of the adjoining owner or
    occupier. Details of approvals shall be submitted to the Engineer in writing.

    3 No workmen employed on the Works shall be allowed to trespass upon adjoining properties.
    QCS 2014 Section 01: General Page 3
    Part 15: Temporary Controls

    4 If in the execution of the Works it is necessary for the Contractor to enter adjacent properties,
    he shall firstly obtain the permission of the owners of the property. The Contractor shall
    ensure that any instructions made by the owners of the properties are strictly adhered to.

    5 The Contractor shall be held responsible for and shall indemnify the Employer against all
    claims, which may arise out of his failure to comply with provisions of items 1. 2. 3 and 4 of
    Clause 1.15.2.4

    15.2.5 Pollution Control

    1 The Contractor shall ensure that none of his operations or work practises result in the
    polluting of the air, underground strata or any existing watercourse, canal, lake, reservoir
    borehole and aquifer.

    2 The Contractor shall rectify any problem resulting from pollution caused by the Contractor to

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    the satisfaction of the Engineer.

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    3 The Contractor will be held responsible for and shall indemnify owner against all claims in
    connection with noise, vibration, dust, smoke, diesel spillage and any other nuisance arising
    from the execution of the Works.

    15.2.6 Surface Water and Groundwater Control ta


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    1 The Contractor shall keep the Work well drained until the Engineer certifies that the whole of
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    the Works is substantially complete and shall ensure that so far as is practicable all work is
    carried out in the dry. Excavated areas shall be kept well drained and free from standing
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    water.

    2 The Contractor shall construct, operate and maintain all temporary dams, water courses and
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    other works of all kinds including pumping and well-point dewatering that may be necessary
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    to exclude water from the Works while construction is in progress. Such temporary works
    shall not be removed without the approval of the Engineer.
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    3 Notwithstanding any approval by the Engineer of the Contractors arrangements for the
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    exclusion of water, the Contractor shall be responsible for the sufficiency thereof and for
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    keeping the Works safe at all times, particularly during periods of rainfall that may result in
    flooding. Any damage to the Works arising through the Contractors failure to provide
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    sufficient protection against water, including flooding, shall be made good at his own
    expense.

    4 It is the Contractors responsibility to dispose of all extracted groundwater and collected


    surface water. The Contractor shall submit details of his proposed disposal methods to the
    Engineer for approval. Discharge of groundwater and/or surface water to existing drainage
    facilities shall only be permitted if written approval is given by Public Works Authority and/or
    concerned other authorities; copies of such approvals shall be submitted to the Engineer.

    5 The Contractor is to take all necessary precautions to avoid floatation of any structure.

    6 The Contractor shall ensure that his groundwater control activities do not adversely affect any
    existing structure or service.
    QCS 2014 Section 01: General Page 4
    Part 15: Temporary Controls

    15.2.7 Environmental protection

    1 The Contractor shall comply with all conditions of the environmental clearance issued for the
    project by the Supreme Council for the Environment and Natural Reserves.

    2 The Contractor shall comply with all rules and regulations regarding environmental protection
    and pollution control issued by the Supreme Council for the Environment and Natural
    Reserves.

    END OF PART

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    QCS 2014 Section 01: General Page 1
    Part 16: Traffic Diversions

    16 TRAFFIC DIVERSIONS................................................................................. 2

    16.1 GENERAL ...................................................................................................... 2


    16.1.1 Scope 2
    16.1.2 Conformance 2
    16.1.3 Safety 2
    16.1.4 System Description 2
    16.1.5 Traffic Police Requirements 2
    16.2 TEMPORARY TRAFFIC DIVERSIONS ......................................................... 3
    16.2.1 General Requirements 3
    16.2.2 Maintenance of Traffic flow 3

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    QCS 2014 Section 01: General Page 2
    Part 16: Traffic Diversions

    16 TRAFFIC DIVERSIONS

    16.1 GENERAL

    16.1.1 Scope

    1 This Part specifies requirements associated with traffic diversions. Traffic diversions include
    for work in, or affecting the use of, roads, footpaths and right of ways and may comprise the
    construction and maintenance of paved and unpaved detour carriageways including all
    earthworks and the provision of adequate drainage, lighting, sign posting, street furniture and
    traffic control devices.

    2 Related Sections and Parts are as follows:

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    This Section Part 4 Protection

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    16.1.2 Conformance

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    1 Signs, control and control devices associated with traffic diversions shall conform to the
    relevant provisions of Traffic Control at Roadworks produced by the Ministry of Public

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    Works (latest edition/version) and shall be to the approval of the Traffic Police and the Public
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    Works Authority.

    16.1.3 Safety
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    1 The Contractor is responsible for all safety issues associated with the installation, operation,
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    maintenance and removal of traffic diversions.


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    2 The Contractor shall provide lighting in accordance with the relevant provisions of Part 4 of
    this Section, Protection.
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    16.1.4 System Description


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    1 Where the diversion of any existing road, footpath or public right or way is temporarily
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    necessitated by the Works, the Contractor shall provide and maintain an alternative which
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    shall be operational before interference with the existing facility.


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    2 Temporary traffic control devices as well as any other traffic management requirement shall
    be erected and maintained by the Contractor for the duration of any activity in, or affecting the
    use of, roads, footpaths and right of ways.

    16.1.5 Traffic Police Requirements

    1 Before any work in, or affecting the use of, any road, footpath, and right of way is
    commenced, the Contractors proposed method of working shall be agreed with, and
    confirmed in writing to, the Engineer and the Traffic Police.

    2 Throughout the execution of the Works and the maintenance period, the Contractor shall co-
    operate with the Traffic Police concerning works in, or access to, roads, footpaths and right of
    ways. The Contractor shall inform the Engineer of any requirements of, or arrangements
    made with, the Traffic Police.
    QCS 2014 Section 01: General Page 3
    Part 16: Traffic Diversions

    16.2 TEMPORARY TRAFFIC DIVERSIONS

    16.2.1 General Requirements

    1 The Contractor shall prepare detailed plans showing any proposed traffic diversions. The
    plans shall fully detail the diversion in all respects and shall include construction details if
    necessary. The plans shall show the position of ramps, traffic signs, cones, barriers,
    demarcation posts and tape, flashing lights and any other traffic control devices. The plans
    shall be submitted to the Engineer for review and shall be approved by the Traffic Police.
    Traffic diversion apparatus shall not be erected until the Traffic Police have reviewed and
    approved the traffic diversion plans.

    2 Persons acting as flagmen shall be physically and mentally qualified, trained in their duties
    and courteous. Each flagman on duty shall be identified with appropriate and distinctive

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    apparel approved by the Engineer and equipped with bilingual STOP/GO signs. Reflective

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    apparel is required for flagging duties during darkness.

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    3 Where paved carriageways, unpaved carriageways or ramps are required, they shall be
    provided and maintained to a standard suitable in all respects for the class or classes of
    traffic or pedestrians requiring the use of them.
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    4 On completion, all traffic diversion works and apparatus shall be removed and land affected
    by them reinstated to its original condition.
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    16.2.2 Maintenance of Traffic flow


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    1 The Contractor shall allow for the construction of temporary diversions to permit all existing
    traffic movements for the duration of the Contract period.
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    2 All diversions shall be constructed in accordance with the latest edition/version of Qatar
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    Traffic Manual Traffic Control at Roadworks booklet and the Qatar Highway Design Manual,
    and shall be approved prior to the implementation by both the Engineer and Traffic Police. It
    is the Contractors responsibility to ensure that any traffic diversion required is properly
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    signed, demarcated, illuminated, controlled and maintained at all times.


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    Upon the Engineers request, the Contractor shall install and commission temporary traffic
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    3
    signals capable of handling the diverted traffic.
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    4 Sequential arrow boards operating on a 24-hour basis (engine or solar powered) must be
    used at all diversion points.

    5 Within the limits of the project where pedestrian traffic is present, all excavated areas,
    regardless of depth, must be cordoned off by means of wired mesh panels of height no less
    than 1.8m connected together to form a continuous barrier wall.

    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 17: Project Co-ordination

    17 PROJECT CO-ORDINATION ........................................................................ 2


    17.1 GENERAL ...................................................................................................... 2
    17.1.1 Scope 2
    17.1.2 Responsibility 2
    17.2 CO-ORDINATION .......................................................................................... 2
    17.2.1 Contractors Activities 2
    17.2.2 Sub-Contractors 3
    17.2.3 Other Contractors 3
    17.2.4 Other Ministries 3
    17.2.5 Liaison with the Public Utility Authorities and other Contractors 3

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    QCS 2014 Section 01: General Page 2
    Part 17: Project Co-ordination

    17 PROJECT CO-ORDINATION
    17.1 GENERAL

    17.1.1 Scope

    1 This Part specifies the co-ordination activities for which the Contractor is responsible.

    2 Related Parts and Sections are as follows:


    This Section Part 18 Other Contractors
    Part 19 Regulatory Requirements

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    17.1.2 Responsibility

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    1 The Contractor shall be responsible for the proper co-ordination of all his activities associated

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    with the construction of the Works including that required between the Engineer, utility
    owners, government departments, sub-contractors and other contractors.

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    No major operations shall be commenced or work outside the usual working hours be carried
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    out without the consent in writing of the Engineer or without full and complete notice also in
    writing being given to him sufficiently in advance of the time of operation so as to enable him
    to make such arrangements as he may deem necessary for its inspection.
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    17.2 CO-ORDINATION
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    17.2.1 Contractors Activities


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    1 The Contractor shall undertake the following co-ordination activities:

    (a) Co-ordinate construction activities under the various Sections of these Specifications
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    to assure efficient and orderly installation of each part of the Works.


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    (b) Co-ordinate construction operations included under the various Sections of this
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    Specification that is dependent upon each other for proper installation, connection, and
    operation.
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    (c) Where installation of one part of the Work is dependent on installation of other
    components, either before or after its own installation, the Contractor shall prepare
    schedules and construction activities in the sequence required to obtain the best
    results.
    (d) Where availability of space is limited, co-ordinate installation of different components
    to assure maximum accessibility for required maintenance, service and repair.
    (e) Make adequate provisions to accommodate items scheduled for later installation.
    (f) Where necessary, prepare memoranda for distribution of each party involved outlining
    special procedures required for co-ordination; include such items as required notices,
    reports and attendance at meetings.
    (g) Prepare similar memoranda for the Engineer, separate contractors and sub-
    contractors where co-ordination of their work is required.
    QCS 2014 Section 01: General Page 3
    Part 17: Project Co-ordination

    (h) Take special care and precautions for specific co-ordination requirements for the
    installation of plant and items of equipment.
    (i) Co-ordinate the scheduling and timing of required administrative procedures with other
    construction activities to avoid conflicts and ensure orderly progress of the work.

    17.2.2 Sub-Contractors

    1 The Contractor is responsible for co-ordinating the work of his sub-contractors in all respects.

    17.2.3 Other Contractors

    1 The Contractor shall co-ordinate his work as necessary with other contractors in accordance
    with the relevant provisions of Part 18, Other Contractors, of this Section.

    .
    17.2.4 Other Ministries

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    1 The Contractor shall co-ordinate his work as necessary with other Ministries in accordance

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    with the relevant provisions of Part 19, Regulatory Requirements, of this Section.

    17.2.5 Liaison with the Public Utility Authorities and other Contractors

    ta
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    1 The Contractor shall liaise with all public utility authorities for water, electricity, telephones,
    etc and shall:
    as

    (a) Provide public utility authorities with storage areas where applicable.
    (b) Assist in unloading of stores and equipment.
    se

    (c) Ensure that all services or diversions of services are installed under the carriageway
    and footways before they are surfaced.
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    (d) Work out an overall programme for any works to be carried out by public utility
    authorities and ensure that this programme is maintained.
    ov

    (e) Keep public utility authorities informed of the Contractors own progress.
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    (f) Arrange for supply of services for all the affected permanent and temporary
    accommodation, buildings, shops, trading areas etc even if it is not clearly mentioned
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    in the Project Documentation for the duration for the Contract:


    et

    (g) Give the appropriate public utility authority adequate notice in writing that he intends to
    m

    install dry ducts so that a representative of the utility concerned may attend the
    installation and record the location of the ducts together with the Contractor.

    2 The Contractor shall make due allowance for carrying out the works, whilst public utility
    authorities are working on the Site, during the Contract period. This due allowance shall
    include programming of the works to suit the programmes of the public utility authorities.

    3 The Contractor shall at all times be responsible for the compliance with these requirements
    of his sub-contractors.

    4 Before final surfacing of any carriageways or footways takes place, the Contractor is
    responsible for ascertaining from all public utility authorities that their underground works
    have been completed. In the event that the Contractor failing to carry out this obligation to the
    satisfaction of the Engineer and completed surfacing is subsequently disturbed, the Engineer
    may instruct the Contractor to carry out work at his own expense.

    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 18: Other Contractors

    18 OTHER CONTRACTORS.............................................................................. 2

    18.1 GENERAL ...................................................................................................... 2


    18.1.1 Scope 2
    18.2 ACCESS FOR OTHER CONTRACTORS ..................................................... 2
    18.2.1 Unhindered Access 2
    18.3 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS 2
    18.3.1 Co-operation at Site Level 2
    18.4 FACILITIES FOR OTHER CONTRACTORS ................................................. 2
    18.4.1 Site Facilities for Other Contractors 2

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    QCS 2014 Section 01: General Page 2
    Part 18: Other Contractors

    18 OTHER CONTRACTORS

    18.1 GENERAL

    18.1.1 Scope

    1 This Part specifies the requirements for access to the Site for other contractors, for
    co-operation and co-ordination with other contractors and for the provision of facilities with
    other contractors.

    18.2 ACCESS FOR OTHER CONTRACTORS

    18.2.1 Unhindered Access

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    1 The Contractor shall allow other contractors unhindered access to any part of the Works
    when in the opinion of the Engineer those parts are sufficiently completed.

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    18.3 CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS

    18.3.1 Co-operation at Site Level ta


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    1 The Contractor shall carry out his work in a manner that causes the minimum amount of
    interference to other contractors working on the Site.
    as

    2 The Contractor shall co-ordinate his operations with the activities of other contractors where
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    necessary in order to avoid conflicts and ensure orderly progress of the Works.
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    3 Those works associated with existing or future service installation shall only be carried out by
    a contractor or sub-contractor approved by the public utility authority concerned. The
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    Engineer shall require proof of such approval in writing prior to the commencement of works.
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    18.4 FACILITIES FOR OTHER CONTRACTORS


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    18.4.1 Site Facilities for Other Contractors


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    1 If specified in the Contract, the Contractor shall provide site facilities for other contractors.

    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 19: Regulatory Requirements

    19 REGULATORY REQUIREMENTS -------------------------------------------------------------------------- 2


    19.1 GENERAL---------------------------------------------------------------------------------------------------------- 2
    19.1.1 SCOPE --------------------------------------------------------------------------------------------------------------- 2
    19.1.2 REFERENCES ------------------------------------------------------------------------------------------------------- 2
    19.2 NOTICES ------------------------------------------------------------------------------------------------------------- 3
    19.2.1 GENERAL ------------------------------------------------------------------------------------------------------------ 3
    19.2.2 NOTICE OF INTENT ------------------------------------------------------------------------------------------------- 3
    19.3 MISCELLANEOUS --------------------------------------------------------------------------------------------------- 3
    19.3.1 W ORK REQUIRED TO BE CARRIED OUT BY THE DEPARTMENT ----------------------------------------------- 3
    19.3.2 REGULATIONS OF ROAD OPENINGS----------------------------------------------------------------------------- 3
    19.4 PROVISION FOR PERSONS WITH DISABILITIES ----------------------------------------------------- 4

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    19.4.1 SCOPE --------------------------------------------------------------------------------------------------------------- 4

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    19.5 THERMAL COMFORT ----------------------------------------------------------------------------------------------- 5

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    19.6 THERMAL INSULATION --------------------------------------------------------------------------------------------- 5
    19.7 ACOUSTICAL CONTROL ------------------------------------------------------------------------------------------- 5
    19.8
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    W ASTE MANAGEMENT -------------------------------------------------------------------------------------------- 5
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    19.8.1 CONSTRUCTION AND DEMOLITION W ASTE --------------------------------------------------------------------- 5
    19.8.2 BULK W ASTE COLLECTION --------------------------------------------------------------------------------------- 6
    19.8.3 W ASTE STORAGE -------------------------------------------------------------------------------------------------- 6
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    19.8.4 W ASTE COLLECTION ---------------------------------------------------------------------------------------------- 6


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    19.8.5 RECYCLABLE W ASTE MANAGEMENT FACILITIES: ------------------------------------------------------------- 6


    19.9 BUILDING FACADE/ EXTERNAL CLADDING MATERIAL -------------------------------------------------------- 7
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    19.9.1 CERTIFICATION AND APPROVAL ---------------------------------------------------------------------------------- 7


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    19.9.2 MATERIAL PROPERTIES ------------------------------------------------------------------------------------------- 7


    19.10 EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS -------------------------- 8
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    19.10.1 GENERAL ------------------------------------------------------------------------------------------------------------ 8


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    19.10.2 MAINTENANCE MANUAL ------------------------------------------------------------------------------------------- 8


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    19.10.3 ACCESS OF CLEANING AND MAINTENANCE -------------------------------------------------------------------- 8


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    19.10.4 CLEANING ----------------------------------------------------------------------------------------------------------- 9


    19.10.5 INSPECTION --------------------------------------------------------------------------------------------------------- 9
    19.11 PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS ------------------------------------------------- 9
    QCS 2014 Section 01: General Page 2
    Part 19: Regulatory Requirements

    19 REGULATORY REQUIREMENTS

    19.1 GENERAL

    19.1.1 Scope

    1 This part specifies the requirements for co-ordination, co-operation and liaison with the
    following utility and infrastructure owners:
    ASHGHAL- Infrastructure Affairs
    ASHGHAL- Building Affairs
    ASHGHAL- Assets Affairs
    Qatar General Electricity & Water Corporation- KAHRAMAA
    Qatar Telecom - Provider

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    Qatar Petroleum, QP

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    Q Rail

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    2 This part also specifies the requirements for co-ordination, co-operation and liaison with the
    following authorities and departments:

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    Authorities having Municipal jurisdiction (Ministry of Energy & Industry, New Industrial area,
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    RLIC, MIC etc.)
    Civil Aviation Authority
    Ministry of Awqaf and Islamic Affairs
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    Ministry of Environment
    Ministry of Interior (Civil Defense Department, Traffic Police, Department of Immigration,
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    Security Systems Department, etc)


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    Ministry of Municipal Affairs and Urban Planning (MMUP)


    Private Engineering Office
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    3 The above shall collectively be known as Department in this Part.


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    4 Related Sections and Parts are as follows:


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    This Section
    Part 16 Traffic Diversions
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    Part 17 Project Co-ordination

    Section 7 Green Construction


    Section 11 Health and Safety
    Section 15 Insulation of Buildings
    Section 25 Glass and Glazing

    5 Where any requirement(s) conflict with any other requirement(s) of Authorities or


    Departments in the State of Qatar, the most stringent requirement(s) shall prevail.

    19.1.2 References
    Al Wakra City Zoning Plan and Regulations Report, 2008, Ministry of Municipality & Urban
    Planning, State of Qatar
    Civil Defense Regulations, Fire Prevention Department, General Administration of Civil
    Defense, Ministry of Interior, State of Qatar
    QCS 2014 Section 01: General Page 3
    Part 19: Regulatory Requirements

    Code on Barrier-Free Accessibility in Buildings, 2002 (ver 1.0), Building and Construction
    Authority, Singapore
    Conditions and Descriptions of the Expedient Workers Residences, Resolution of the
    Minister of Civil Service and Housing Affairs No. (17) of 2005, State of Qatar
    NFPA 101 Life Safety Code, 2012 Edition, National Fire Protection Association, U.S.A.
    Planning and Building Regulations for Flats & Flat Complexes, 1994, Planning Department,
    Ministry of Municipal Affairs & Agriculture, State of Qatar
    Planning and Building Regulations for Villas & Villa Complexes, 1995, Planning Department,
    Ministry of Municipal Affairs & Agriculture, State of Qatar
    Qatar Highway Design Manual, 1997 (Rev 0), Civil Engineering Department, Ministry of
    Municipal Affairs & Agriculture, State of Qatar
    Qatar Survey Manual, UPDA, The Centre for GIS State of Qatar.
    Qatar Traffic Manual Vol. 1

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    Qatar Traffic Manual Vol. 2

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    Universal Design Guidelines, 2006, Building and Construction Authority, Singapore

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    19.2 NOTICES

    19.2.1 General ta
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    1 All notices required to be given by the Contractor to the Department shall be in writing and
    delivered by hand. The Contractor shall furnish the Engineer with a copy of all notices
    as

    issued by the Contractor.


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    19.2.2 Notice of Intent


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    1 The Contractor shall give at least seven days notice to the Department of the date upon
    which it is intended to operate plant or equipment or carry out any work for which permission
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    has been given in writing by the Department: such operations or work shall only be carried
    out in the presence a representative of the Department unless written confirmation shall
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    have been obtained that this unnecessary.


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    19.3 MISCELLANEOUS
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    19.3.1 Work required to be carried out by the Department

    1 If the Department requires work to be carried out on its installations during the execution of
    the Works, the Contractor shall provide all facilities to the Departments contractor or
    workmen. The Contractor shall co-ordinate the work of the Department and his own
    activities, and when necessary shall amend his programme to suit the requirements of the
    Department and shall keep the Engineer informed of all arrangements made.

    19.3.2 Regulations of Road Openings

    1 For Works including road openings, the Contractor shall comply with all relevant provisions
    of the following Parts of this Section or direction of the Engineer.
    Part 16 Traffic Diversions.
    Part 21 Final Inspection and Handover
    QCS 2014 Section 01: General Page 4
    Part 19: Regulatory Requirements

    19.4 PROVISION FOR PERSONS WITH DISABILITIES

    19.4.1 Scope

    1 The aim of this provision is to set out the fundamental design and construction requirements
    and guidelines for making those buildings specified in Table 1 accessible to persons with
    disabilities.
    Table 1: Accessibility for Persons with Disabilities
    No Types of buildings Accessible areas
    1 Residential buildings:
    (a) 3-storeys and below All communal areas and facilities at ground floor.
    (b) 4-storeys and above All communal areas and facilities.

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    2 Office buildings All areas intended for access by employees or

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    public.

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    3 Shophouses The ground floor for non-residential use shall be
    accessible to employees or public.
    4 Shopping complexes and multipurpose All areas intended for access by employees or
    complexes public.
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    5 Hotels and boarding houses All areas intended for access by employees or
    public.
    6 Religious buildings and Mosques All areas intended for access by worshippers or
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    public.
    7 Places of public resort All areas intended for access by employees or
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    public.
    8 Cinemas, theatres, concert halls, stadia All areas intended for access by employees or
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    or other places of public resort where public.


    permanent seating arrangement is
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    provided
    9 Schools, colleges, universities or All areas intended for access by employees or
    institutions of learning public.
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    10 Hostels, halls of residence or dormitories All areas intended for access by staff, students or
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    public.
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    11 Sports complexes and public swimming All areas intended for public access.
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    pools
    12 Restaurants and eating establishments All areas intended for access by employees or
    public.
    13 Markets and hawker or food centres All areas intended for public access.
    14 Hospitals, clinics, dispensaries, nursing All areas intended for access by staff, patients,
    homes, homes for the aged and welfare inmates or public.
    homes
    15 Factories, workshops and industrial All areas intended for access by employees or
    buildings 4-storeys and above public.
    16 Transport stations, interchanges, All areas intended for access by employees or
    passenger terminals and administration public.
    buildings in depots
    17 Vehicle parks (surface parking or vehicle Prescribed areas.
    parking buildings)
    QCS 2014 Section 01: General Page 5
    Part 19: Regulatory Requirements

    2 The Owner is recommended to follow and adopt suitable and relevant international barrier
    free access guidelines which will allow persons with disabilities to enter, move around and
    leave an establishment without hindrances.

    3 Universal Design is a continuous process of innovation targeted at improving usability for


    everyone. It is also known that Universal Design is the design of products and environment
    to be usable by all people, to the greatest extent possible, without the need for adaptation or
    specialised design. It is highly recommended that the Owner adopt Universal Design until the
    authority (MMUP) approve reference.

    19.5 THERMAL COMFORT

    1 The heating, ventilation and air conditioning (HVAC) system must be capable of providing
    the following range of conditions for 95% of the year

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    Lower Limit Upper Limit
    DB: 22.5 C DB: 25.5 C

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    Dry bulb temperature
    Relative humidity RH: 30% (min) RH: 60% (max)

    2
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    For occupant comfort, normal occupied spaces should have a terminal air velocity between
    qa
    (0.2-0.3) m/s.

    19.6 THERMAL INSULATION


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    1 As specified in section 15
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    19.7 ACOUSTICAL CONTROL


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    1 As specified in section 15
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    19.8 WASTE MANAGEMENT


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    19.8.1 Construction and Demolition Waste


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    1 For all new buildings unless or until specified otherwise, at least fifty percent (50%) by
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    volume or weight of waste material generated during the construction and/ or demolition of
    buildings must be diverted from disposal in landfills. Diverted materials must be recycled or
    reused.

    2 This should be done through one or more of the following three paths:
    (a) Concrete and Asphalt waste must be diverted to Construction Waste Treatment Plant.
    (b) Excavated soil, land-clearing debris and hazardous waste must be diverted to places
    designated by the concerned Department of MMUP.
    (c) Other recyclable materials such as woods plastics and metals can be used at site or
    diverted to a Recycling Facility.

    3 The following materials are exempt from the calculation of the percentage of waste diverted
    from disposal at landfill facilities:
    (a) Excavated soil and land-clearing debris; and
    (b) Hazardous waste
    QCS 2014 Section 01: General Page 6
    Part 19: Regulatory Requirements

    19.8.2 Bulk Waste Collection

    1 For all new residential apartment buildings, an area must be provided for residents to place
    items of bulky waste such as furniture, electrical appliances and sanitary ware. The area
    2
    provided must cover a space of approximately ten square meters (10 m ). The area does not
    have to be designated solely for the purpose of bulky waste collection (eg: set aside to the
    car park).

    2 The bulky waste storage area must be reachable, must not restrict access to the building
    and comply with safety and fire requirement.

    19.8.3 Waste Storage

    1 For all new villas and apartments (single family units), domestic kitchen must be provided
    with a minimum storage facility of two ten (10) liter waste receptacles clearly labeled for

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    recyclable and non-recyclable. The storage facility should be in a proper place within the

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    kitchen.

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    19.8.4 Waste Collection

    1
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    All new buildings which require chute for general waste, in accordance with Qatar MMUP
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    Regulations, one of the following must be provided:
    (a) A second chute must be provided to handle recyclable material and discharge into a
    separate receptacle within the waste management area; or
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    (b) The garbage room on each floor must have a minimum floor area of two square
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    2
    meters (2 m ) where recyclable waste can be stored until collected daily by the
    building operator. Waste must be transported through designated medium (chute,
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    service elevator etc.) into the waste management area.


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    2 All new buildings which does not require chute for general waste, in accordance with Ministry
    of Municipal Affairs and Urban Planning Regulation, the garbage room on each floor must
    2
    have a minimum floor area of three square meters (3 m ) where non-recyclable and
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    recyclable waste can be stored until collected daily by the building operator. Waste must be
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    transported in a service left discharge into a designated receptacle within the waste
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    management.
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    19.8.5 Recyclable Waste Management Facilities:

    1 For all new buildings other than villas, a sorting and storage facility for recyclable materials
    must be provided.

    2 This facility must be easily accessible and comply with the requirements of the location,
    access and specifications of general waste areas in accordance with Qatar Municipality
    Building Regulations.

    3 The sorting and storage facility may be part of the general waste management facility or a
    separate facility.
    (a) Recycled waste facility incorporated into the general waste collection:

    2
    The size of the room must be increased by 10% and not less than 5 m , to allow
    additional room to sort and store the recyclable waste.
    QCS 2014 Section 01: General Page 7
    Part 19: Regulatory Requirements

    (b) Recycled waste facility separated from the general waste collection:

    The recycled waste facility must be sized as a percentage from the total Built Up Area
    (BUA) of the building in accordance with Table 2.
    Where the Total Built Up Area (BUA) of the building falls between the figures outlined in the
    Table, linear interpolation must be used to determine an appropriate percentage area for the
    recyclable storage space.

    Table 2: Sizing Requirements for Storage of Recyclables


    Built Up Area (BUA) Minimum Space for Storage of Recyclables
    2
    Less than 500 m2 7.5m
    2
    500 m 1.5% of BUA
    2
    1,000 m 0.8% of BUA

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    5,000 m 0.35% of BUA
    2
    10,000 m or greater 0.25% of BUA

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    19.9 BUILDING FACADE/ EXTERNAL CLADDING MATERIAL

    19.9.1 Certification and approval ta


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    1 External Cladding material must be tested by an approved 3 party test laboratory. The
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    manufacturer shall have certified ISO 9000 compliant QMS.

    2 External Cladding materials that are combustible must be submitted to the Qatar Civil
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    Defense for review and approval. Submissions shall include copies of relevant test reports
    and details on the proposed fixings used to secure the material to the building. On approval,
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    a Qatar Civil Defense certificate for the External Cladding material will be issued to the
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    submitting party.

    19.9.2 Material properties


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    1 External Cladding Material (ECM) fixed to buildings shall be non-combustible and shall be
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    composed of environmentally friendly materials and substances.


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    2 ECM not complying with 19.8.2.1 above must have the following fire propagation and flame
    spread properties.
    (a) When tested in accordance with BS 476 Part 6:
    (i) Fire Propagation index, no greater than 4.0
    (ii) any sub index must not be greater than 2.0, and
    (b) When tested in accordance with BS 476 Part 7:
    (i) flame spread after 10 minutes must be less than 25 mm

    3 Alternative test methods and Standards such as AS, BSI and ISO may be used to verify
    compliance in test reports provided the method of testing is demonstrated to be equivalent
    and verifies an equal or better fire performance result to those nominated in 19.8.2.2 above.

    4 Details of the ECM's approval and listings, its method of fixing and the extent of usage shall
    be included in the proposed Building Plans fire safety submission for compliance verification.
    QCS 2014 Section 01: General Page 8
    Part 19: Regulatory Requirements

    19.10 EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE


    BUILDINGS

    19.10.1 General
    1. Any building measuring 28 meters or above in height is classified as a high rise building as
    per Qatar Civil Defense Department. This section is intended to provide a framework for the
    cleaning and maintenance of the faade for high rise buildings. The faade will require both
    cleaning and maintenance to achieve its anticipated life and desired purpose. Failure to
    undertake this work can considerably reduce the life of materials, components and finishes.
    The provision of correct documentation and instruction at the completion of construction will
    permit the building owner to gain the best achievable performance from the faade.

    19.10.2 Maintenance Manual

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    1 A maintenance manual should be produced for the completed works. The number and

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    specific requirements for the manual should be specified at tender stage. The manual should

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    be developed in parallel with the design and should include, but not be limited to, the
    following information:
    (a)
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    The name, address and telephone number of each firm and/ or sub-contractor
    involved in the supply of materials, components, assemblies and finishes.
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    (b) A clear and concise description of the construction used to form the various areas of
    faade on the particular project.
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    (c) Copies of material, component and finishes certification and test reports as required
    by the Specifier.
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    (d) A method statement showing the means of access to all parts of the wall and safe
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    loadings.
    (e) A method statement covering the procedures for replacement of damaged or
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    otherwise defective materials or components, and materials and components that


    have a design life less than the design of the faade and will therefore require
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    replacement during the life of the faade.


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    (f) Recommendations for routine maintenance, cleaning, suitable cleaning agents and
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    any lubrication/adjustments to working parts.


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    (g) A full set of construction drawings updated to include any changes made up to the
    time of completion.
    (h) The terms and conditions of any guarantees.

    19.10.3 Access of Cleaning and Maintenance

    1 The Building Owner/ Specifier should provide a means of access which enables all parts of
    the faade to be safely reached for the purpose of cleaning, inspection and maintenance.
    The intended method of access should be established at the design stage and the relevant
    loads catered for. Particular care should be made to define all possible imposed loads
    including impact loads and uplift forces on projections by snagging.

    2 The access system should comply with the appropriate British Standards (BS 6037, BS
    5974). Specifiers should also make themselves aware of any statutory obligations related to
    Occupational Health and Safety at Work.
    QCS 2014 Section 01: General Page 9
    Part 19: Regulatory Requirements

    3 The access system should not be capable of imparting forces upon the cladding system
    exceeding those agreed at the design stage. It is important that the various parties agree the
    design parameters early in the design process.

    4 The access equipment should be maintained, examined periodically by a competent person


    and certified in accordance with statutory regulations.

    19.10.4 Cleaning

    1 The supplier of the faade should provide instruction for the proper cleaning and routine
    maintenance of the faade.

    2 Cleaning of the faade should be undertaken by trained personnel working to an agreed


    procedure, based upon the faade contractors recommendations, at a frequency not less
    than the recommended intervals.

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    19.10.5 Inspection

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    1 The faade should be inspected at regular intervals to an agreed method. The faade
    contractor, in consultation with the project team, should suggest methods and procedures to

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    be utilized. The purpose of this inspection includes, but is not necessarily limited to, the
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    following:
    (a) To review the effectiveness of cleaning methods employed.
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    (b) To monitor the performance of the materials and components of the faade system
    against their anticipated life.
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    (c) Inspecting for damage or failure of any part of the system.


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    (d) Checking on the effectiveness of maintenance or remedial work.


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    2 It is recommended that a detailed inspection plan is drawn up at the time of construction in


    consultation between the design and construction teams. The inspection plan should include
    procedures and recording methods to enable a systematic monitoring of the condition of the
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    Curtain wall and assist in the prediction of the need for preventative maintenance or
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    replacement of component parts.


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    3 Inspections should be carried out by suitably experienced persons to the specific procedures
    detailed in the inspection plan. The results of these inspections should be compared with
    previous inspections where appropriate. The building owner should ensure these results are
    available for reference.

    19.11 PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS

    1 The public buildings, for the purpose of provision of Ablution facilities are considered to be
    Offices, Shopping Centres, Malls and Hypermarkets.

    2 The occupant load (population) for each building type shall be calculated as per guidelines of
    Qatar Civil Defense Department.

    3 Separate Ablution facilities are to be provided for Men and Women close to the Prayer Area.
    QCS 2014 Section 01: General Page 10
    Part 19: Regulatory Requirements

    4 The number of Ablution stalls shall be calculated as per Table 3 below.

    Table 3: Provision of Ablution Facility


    Facility Type Occupant Population No. of Ablution Stalls

    Up to 50 02
    Office Building
    01
    For 51 and above
    For each additional 50
    Up to 200 02
    Shopping Mall
    01
    For 201 and above
    For each additional 200
    Up to 200 02

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    Shopping Centre 01
    201- 2000 people
    Hypermarket For each additional 400

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    01
    For 2001 and above
    For each additional 1000

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    END OF PART
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    QCS 2014 Section 01: General Page 1
    Part 02: Use and Maintenance of the Site

    2 USE AND MAINTENANCE OF THE SITE ............................................................... 2


    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.2 USE OF THE SITE .................................................................................................. 2
    2.2.1 General 2
    2.3 MAINTENANCE OF THE SITE................................................................................ 2
    2.3.1 General 2

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    QCS 2014 Section 01: General Page 2
    Part 02: Use and Maintenance of the Site

    2 USE AND MAINTENANCE OF THE SITE

    2.1 GENERAL

    2.1.1 Scope

    1 This Part specifies the uses and maintenance requirements of the Site.

    2 Related Sections and parts are as follows:


    This Section Part 10 Occupational Health and Safety
    Part 11 Engineers Site Facilities
    Part 12 Contractors Site Facilities

    2.2 USE OF THE SITE

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    2.2.1 General

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    1 The Site shall not be used for any purpose other than that of carrying out the Works.

    2
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    Temporary camps, housing and cooking facilities shall not be permitted on the Site unless
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    otherwise stated in the Project Documentation. When temporary camps, housing and
    cooking facilities are permitted they shall comply with Section 1 Part 10.
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    2.3 MAINTENANCE OF THE SITE


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    2.3.1 General
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    1 In accordance with the Conditions of Contract the Site, the equipment used upon it and the
    Works shall be kept clean at all times.
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    END OF PART
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    QCS 2014 Section 01: General Page 1
    Part 20: Clearance of the Site

    20 CLEARANCE OF SITE ............................................................................................ 2


    20.1 GENERAL ............................................................................................................... 2
    20.1.1 Scope 2
    20.2 FINAL CLEARING ................................................................................................... 2
    20.2.1 General 2
    20.2.2 Internal and External Surfaces 2
    20.2.3 The Site 2
    20.2.4 Miscellaneous 3

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    QCS 2014 Section 01: General Page 2
    Part 20: Clearance of the Site

    20 CLEARANCE OF SITE

    20.1 GENERAL

    20.1.1 Scope

    1 This Part specifies the requirements for the final clearance of the Site.

    20.2 FINAL CLEARING

    20.2.1 General

    1 Final clearing shall be done before the final inspection.

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    2 All waste materials shall be removed from the Site and disposed of properly.

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    20.2.2 Internal and External Surfaces

    1 The Contractor shall clean all interior and external surfaces exposed to view. The Contractor

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    shall undertake the following to the satisfaction of the Engineer:
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    (a) Remove temporary labels, stains and foreign substances.
    (b) Polish transparent and glossy surfaces.
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    (c) Clean roofs, gutters, downspouts, and drainage systems.


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    (d) Remove debris and surface dust from limited access spaces.
    (e) Broom clean concrete floors and unoccupied spaces.
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    (f) Clean light fixtures and lamps so they operate at maximum efficiency.
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    (g) Other cleaning tasks as specified by the Engineer.


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    20.2.3 The Site


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    1 The Contractor shall clean the Site and shall undertake the following to the satisfaction of the
    Engineer:
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    (a) Sweep paved areas and rake all other surfaces.


    (b) Remove litter and foreign substances.
    (c) Remove stains, chemical spills and other foreign deposits.
    (d) Any other cleaning tasks as specified by the Engineer.

    2 The Contractor shall abide by the latest regulations of the Ministry of Municipal Affairs and
    Agriculture and relevant municipalities in clearance of construction works refuse.
    QCS 2014 Section 01: General Page 3
    Part 20: Clearance of the Site

    3 Clearance and transportation of construction works refuse:

    (a) The Contractor shall undertake to carry out the following within a maximum period of
    30 days after completion of the agreed building or project and preparing it for use or
    stoppage of work for an indefinite period.
    (i) Removal of the entire Contractors equipment, machinery and other belongings
    from the work site.
    (ii) Clearance of all earth, debris and refuse whatsoever and transporting them to
    the location designated by the concerned municipality, delivering the building or
    project absolutely clean and free of any such materials and delivery of the
    surrounding area levelled to the natural level of the street pavement.
    (b) In the case of Contractors delay or refusal to carry out such a job, he shall have to pay
    a penal compensation as defined in the contract for delay for each day or part of day.

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    This compensation shall be final and the judiciary shall not be entitled to mitigate it and

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    it does not require establishing the occurrence of any damage to the owner.

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    (c) In addition, the Owner shall be entitled to clear the refuse himself and transport it to the
    location designated by the concerned municipality. The Owner shall deduct the cost of
    refuse clearance, transport and any other related costs including the office expenses

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    and overhead cost from the payment or the money due to the Contractor. He may also
    stop the final payment due to the Contractor until such refuse has been cleared and a
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    certificate confirming this has been obtained from the concerned Municipality.

    20.2.4 Miscellaneous
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    1 The Contractor shall clean or replace all mechanical filters for equipment included in the
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    Works and for equipment directly affected by the construction of the Works.
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    END OF PART
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    QCS 2014 Section 01: General Page 1
    Part 21: Final Inspection and Handover Procedures

    21 FINAL INSPECTION AND HANDOVER PROCEDURES .............................. 2

    21.1 GENERAL PROCEDURES FOR INSPECTION AND HANDOVER .............. 2


    21.1.1 Scope 2
    21.1.2 Pre-requisite for Final Inspection 2
    21.1.3 Approvals from Public Authorities 3
    21.1.4 Hand Over 3
    21.2 ITEMS TO BE PROVIDED BY THE CONTRACTOR .................................... 4
    21.2.1 Provision of Tools, Spare Parts and Maintenance Materials 4
    21.2.2 Guarantee Warrantees and Bonds 4
    21.3 MECHANICAL AND ELECTRICAL WORKS ................................................. 4

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    21.3.1 Operation Data 4

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    21.3.2 Operation and Maintenance Manuals 4
    21.3.3 Operational, Field and Performance Testing 5

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    21.4 PROJECT RECORD DOCUMENTS.............................................................. 5
    21.4.1
    21.4.2
    General
    Record Drawings ta 5
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    21.4.3 Record Specifications 6
    21.4.4 Maintenance Period Final Inspection 6
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    QCS 2014 Section 01: General Page 2
    Part 21: Final Inspection and Handover Procedures

    21 FINAL INSPECTION AND HANDOVER PROCEDURES


    21.1 GENERAL PROCEDURES FOR INSPECTION AND HANDOVER

    21.1.1 Scope

    1 This Part specifies the requirements and procedures associated with the inspection and
    handover of the Works.

    2 Related sections and Parts are as follows:


    This Section Part 7 Submittals
    Part 9 Materials
    Part 20 Clearance of Site

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    Section 2 Quality Assurance and Quality Control
    Section 9 Mechanical and Electrical Equipment

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    21.1.2 Pre-requisite for Final Inspection

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    The Contractor shall complete the following to the satisfaction of the Engineer before
    requesting the pre-handover Inspection:
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    (a) Submit final manufacturer certification, guarantees, warranties and similar documents.
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    (b) Submit occupancy permits, operating certificates, final inspection and test certificates
    and similar releases enabling full and unrestricted use of the Works.
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    (c) Submit record drawings, operation and maintenance manuals, final project
    photographs, damage or settlement surveys, property surveys and similar physical
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    items.
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    (d) Complete submittal of record documents.


    (e) Make final changeover of locks and deliver the keys to the Engineer.
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    (f) Complete start-up, testing of system, and training of the Owners operations and
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    maintenance personnel; submit equipment operating data as well as all test reports
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    and test data required by the Contract.


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    (g) Dismantle and remove temporary facilities and services from the Site; this includes
    utilities, construction tools, buildings and facilities, mock-ups, and similar elements
    (h) Complete final cleaning.
    (i) Repair and restore exposed finishes which have been marred or otherwise damaged.
    (j) Handover all spare parts, tools and maintenance equipment.
    (k) In Network Projects, partial handling over would be acceptable, if it completely met all
    the above mentioned requirements.
    (l) Closure of all identified Non-conformance and deficiencies to the satisfaction of the
    Engineer
    QCS 2014 Section 01: General Page 3
    Part 21: Final Inspection and Handover Procedures

    2 When the Contractor has completed and cleaned the Works to the satisfaction of the
    Engineer the Contractor shall request a final inspection. The request shall be forwarded to
    the Owner by the Engineers Representative and a suitable date for the inspection shall be
    arranged. The Contractor, Engineers Representative, maintenance department (if any) and
    the supervising consultant (if any) shall be present. A list of outstanding items (if any) shall
    be agreed and issued to the Contractor.

    3 Upon completion of the listed outstanding items a further inspection shall be requested by the
    Contractor, the request shall be forwarded to the Owner by the Engineers Representative
    and a suitable date for the inspection shall be arranged. The Contractor, Engineers
    Representative, maintenance department (if any) and the supervising consultant (if any) shall
    be present.

    4 A list of any items still outstanding shall be issued to the Contractor. If any of these are
    deemed to be significant the Contractor shall complete these items and then request another

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    inspection as described in clause 21.1.2-2.

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    5 In respect of pumping station or Works involving mechanical or electrical equipment if items
    outstanding are deemed not to be significant or if no outstanding items remain then a 7 day
    commissioning and running test shall be initiated. On completion of all tests and agreement

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    by the Engineers Representative that the plant is considered operable then it shall be
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    handed over. A 14 day training period for the maintenance department staff on the operation
    of the pumping station shall commence.
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    6 For works that have no mechanical or electrical equipment if the outstanding items are
    deemed not to be significant or if no outstanding items remain the Works inspected shall be
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    handed over.
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    21.1.3 Approvals from Public Authorities


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    1 The Contractor shall obtain all clearance certificates and approvals required as a prerequisite
    to connecting the Works to the permanent water and/or power supply.
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    2 The Contractor shall co-ordinate with the Engineer to obtain the necessary documents from
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    the Qatar General Electricity & Water Corporation regarding connection to the permanent
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    water and/or power supply.


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    21.1.4 Hand Over

    1 When the Contractor considers that the Works are complete he shall submit the following:

    (a) A certificate stating that the Works are complete and that all the requirements of the
    Project Documentation have been met.
    (b) A certificate stating that the Works have been inspected.
    (c) A certificate from the appropriate Municipality regarding cleanliness of the Site.
    (d) Approval from the PWA regarding satisfactory trench reinstatement in the Highway (if
    applicable).
    QCS 2014 Section 01: General Page 4
    Part 21: Final Inspection and Handover Procedures

    21.2 ITEMS TO BE PROVIDED BY THE CONTRACTOR

    21.2.1 Provision of Tools, Spare Parts and Maintenance Materials

    1 The Contractor shall provide all tools, spare parts and maintenance materials specified in the
    Project Documentation.

    2 The Contractor shall provide an itemised list of all the items to be furnished under this
    Clause. Each item to be furnished shall be given a unique reference number. The list shall
    include the reference number, a description of the item and the appropriate Specification
    Section and Paragraph.

    3 All the items furnished under this Clause shall be packaged for long term storage. Any items
    requiring special storage conditions shall be brought to the attention of the Engineer.

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    4 All items furnished under this Clause shall be provided with a mark or tag for identification

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    purposes. The mark or tag shall include the reference number detailed in Clause 21.2.1-2.

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    5 Unless otherwise instructed, all items furnished under this Clause shall be delivered to the
    Government Stores in accordance with the relevant provision of Part 9 of this Section,
    Materials.
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    21.2.2 Guarantee Warrantees and Bonds
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    1 The Contractor shall provide notarised copies of all guarantees, warranties and bonds as
    required by the Project Documentation. The guarantees, warranties and bonds should be
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    assembled in a binder with a durable plastic cover, complete with a table of contents.
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    2 The start of the warranty or guarantee period shall be either:

    The date when any item is placed into full time operation for the Governments benefit
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    (a)
    and with the Engineers approval.
    (b) The date of issue of the completion certificate.
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    21.3 MECHANICAL AND ELECTRICAL WORKS


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    21.3.1 Operation Data

    1 The Contractor shall provide all operating data for all mechanical and electrical equipment
    supplied under the Contract.

    2 The operating data shall be presented on A4 size paper in ring binder with a durable plastic
    cover.

    21.3.2 Operation and Maintenance Manuals

    1 The Contractor shall provide approved Operation and Maintenance Manuals in accordance
    with the relevant provisions of Section 9, Mechanical and Electrical Equipment and Part 7 of
    this Section, Submittals.
    QCS 2014 Section 01: General Page 5
    Part 21: Final Inspection and Handover Procedures

    21.3.3 Operational, Field and Performance Testing

    1 After all construction and starting is complete and before taking-over of any part of the
    Works, the Contractor shall perform operational, field and performance tests as called for in
    the Project Documentation.

    2 The Contractor shall demonstrate operation of the facilities of the Engineer showing proper
    sequence of operation as well as satisfactory performance of the system and individual
    components. Any improper operation of the system or any improper, neglected or faulty
    construction shall be repaired or corrected to the satisfaction of the Engineer. The Contractor
    shall make such changes, adjustments or replacement of equipment as may be required to
    make same comply with the Specifications, or replace any defective parts or material.

    3 Failure of the system to perform at the specified level at the time of testing will be the
    responsibility of the Contractor. In the event of failure of equipment to meet the specified

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    performance, the Owner reserves the right to reject such equipment or system, withhold

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    retention money or make claims on the Performance Bond.

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    4 The Contractor shall submit a consolidated schedule of operation, field and performance
    tests no later than three (3) months before the schedule start of the first test and weekly a

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    schedule of tests to be carried out the following week. The Contractor shall inform the
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    Engineer not later than 24 hours in advance of changes in the scheduling of a test.

    5 For all specified performance tests, the Contractor shall prepare and submit the following:
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    (a) A draft test procedure no later than two (2) months in advance of the schedule test
    date.
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    (b) A final test procedure no later two (2) weeks in advance of the scheduled test date.
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    (c) A test report within two (2) weeks of the successful completion of the test.
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    21.4 PROJECT RECORD DOCUMENTS


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    21.4.1 General
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    1 Project Record Documents shall be kept separate from construction/working documents.


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    2 Project Record Documents shall be stored in facilities that provide a suitable environment to
    prevent damage or deterioration and to prevent loss.

    3 Project Record Documents shall include, but not be limited to the following:

    (a) Drawings.
    (b) Specifications.
    (c) Addenda.
    (d) Variation orders.
    (e) Correspondence.
    (f) Transmittals
    (g) Inspection and Test Records
    QCS 2014 Section 01: General Page 6
    Part 21: Final Inspection and Handover Procedures

    21.4.2 Record Drawings

    1 Record drawings shall be clearly and correctly red-marked by the Contractor to show all
    changes made during the construction process. The record drawings shall show the Works
    as executed in accordance with the relevant provisions of Part 7 of this Section - Submittals.

    21.4.3 Record Specifications

    1 Record specifications shall be clearly and correctly annotated to show all changes made
    during the construction process.

    21.4.4 Maintenance Period Final Inspection

    1 During the last month of the period of maintenance the Engineer will notify the maintenance
    department that the maintenance period is about to expire. An inspection of the Works by

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    the Engineers Representative, maintenance department, and the Contractor shall be

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    undertaken to verify that all outstanding items have been completed.

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    END OF PART

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    QCS 2014 Section 01: General Page 1
    Part 22: New Technologies and Innovations

    22 NEW TECHNOLOGIES AND INNOVATIONS............................................... 2

    22.1 GENERAL PROCEDURES FOR APPROVAL............................................... 2


    22.1.1 Scope 2
    22.1.2 Pre-requisite for Approval 2
    22.1.3 Technologies And Innovations Of Interest 2
    22.1.4 Documentation 3
    22.1.5 Final Inspection And Approval 3

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    QCS 2014 Section 01: General Page 2
    Part 22: New Technologies and Innovations

    22 NEW TECHNOLOGIES AND INNOVATIONS


    22.1 GENERAL PROCEDURES FOR APPROVAL

    22.1.1 Scope

    1 Qatar is committed to researching and using new technology and innovations within
    construction industry. Because of this commitment it is open to proposals from outside
    agencies in the use of new technologies and innovations.

    2 This Part specifies the requirements associated with the proposal and approval of new
    technologies and innovations for use in construction in Qatar.

    22.1.2 Pre-requisite for Approval

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    1 New technologies / innovations are allowed for use in any project on experimental or

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    research basis after getting an approval from National Committee For Construction and
    Building materials Specifications (NCCBS) of the Ministry of Environment and any other
    concerned parties.

    2 ta
    The period allowed for such an experiment or research shall be limited to a trial period of a
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    maximum of two years after which it will be evaluated prior to approval or otherwise by the
    concerned parties.
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    3 The supplier will be required to submit a guarantee certificate for an agreed period of time.
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    4 The supplier shall submit a written warranty to bear all fiscal and legal responsibilities as a
    result of using the experiment if not meeting the suppliers claims/specifications. He shall
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    remove any material or debris left from the experiment.


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    22.1.3 Technologies And Innovations Of Interest


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    1 The following are of particular interest to Qatar :


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    (a) Polymer Modified Bitumen (PMB)


    (b) Superpave
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    (c) Performance Grade Binders suitable for the climatic conditions of Qatar (i.e. PG 76-10)
    (d) Cold Laid Asphalt
    (e) Rubber Recycling
    (f) Stone Mastic Asphalt (SMA)
    (g) Glass Reinforced Plastic (GRP) pipes
    (h) Polyethylene (PE) Plain and Corrugated pipes
    (i) Fibre Reinforced Concrete
    (j) Recycling of materials from demolished buildings and roads

    2 Notwithstanding the above Qatar wishes suppliers to propose technology and innovations
    that it believes can benefit Qatar and the environment.
    QCS 2014 Section 01: General Page 3
    Part 22: New Technologies and Innovations

    22.1.4 Documentation

    1 The technology provider shall be requested to submit with his proposals the following
    documents:

    (a) Drawings
    (b) Specifications
    (c) Technology Reference and Manual
    (d) Specifications and Source
    (e) Reference from previous clients
    (f) Transmittals
    (g) Inspection and Test Records

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    (h) Health and Safety requirements

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    (i) Environmental requirements

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    (j) Material Safety Data Sheet (MSDS) regarding but not limited to transportation,
    handling & storage, and First Aid requirements
    (k) Financial arrangements ta
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    22.1.5 Final Inspection And Approval
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    1 Final approval of the technology will be dependant on NCCBS visits, inspection and tests.
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    Upon satisfaction of the committee, written approval shall be given and the specifications
    incorporated into the QCS.
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    END OF PART
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    QCS 2014 Section 01: General Page 1
    Part 23: Design & Supervision Consultant Quality Requirements

    23 DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS................................ 2


    23.1 GENERAL ............................................................................................................... 2
    23.1.1 Scope 2
    23.1.2 References 2
    23.1.3 Definitions 2
    23.2 DESIGN CONSULTANT QUALITY REQUIREMENTS ............................................ 3
    23.2.1 Quality Responsibility and Duties 3
    23.2.2 Quality System Documentation 3
    23.2.3 Quality Plan 4
    23.2.4 Construction Inspection and Test Requirements Specification 5
    23.2.5 Design Consultant Verification of Sub Consultants 5
    23.2.6 Quality Records 5

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    23.3 SUPERVISION CONSULTANT QUALITY REQUIREMENTS.................................. 5

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    23.3.1 Quality Responsibilities and Duties 5

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    23.3.2 Quality System Documentation 7
    23.3.3 Quality Plan 8
    23.3.4 Inspection and Test Plans (ITPS) 9
    23.3.5 Technical Procedures, Work Instructions and Method Statements ta 9
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    23.3.6 Monitoring by Supervision Consultants 10
    23.3.7 Review of Contractor Quality Documentation 10
    23.3.8 Inspection Responsibilities 11
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    23.3.9 Inspections and Test Surveillance Points 11


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    23.3.10 Visits 12
    23.3.11 Supervision Consultant Verification 12
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    23.3.12 Interfacing 12
    23.3.13 Punch Lists 12
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    23.3.14 Protection of the Works 12


    23.3.15 Quality Records 12
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    QCS 2014 Section 01: General Page 2
    Part 23: Design & Supervision Consultant Quality Requirements

    23 DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS


    23.1 GENERAL

    23.1.1 Scope

    1 This Part specifies the Quality Assurance activities to be performed by Design and
    Supervision Consultants during all phases of the Contract and should be read in conjunction
    with all other parts of the Contract.

    2 The purpose of this part is to define Design and Supervision Consultants responsibility for
    demonstrating that the work under the contract is executed to the quality standards required
    by the contract and to outline verification activities.

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    23.1.2 References

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    1 The following standards are referred to in this part:
    BS EN ISO 9000:2005 Quality Management systems. Fundamentals and vocabulary
    BS EN ISO 9001:2008
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    Quality Management systems. Requirements
    BS ISO 10006:2003 ...Quality Management systems, Guidelines for Quality Management in
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    Projects
    BS ISO 10005:2005 ...Quality Management systems. Guidelines for Quality Plans
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    BS EN ISO 19011:2011 Guidelines for auditing management systems


    QCS Qatar Construction Specification
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    23.1.3 Definitions
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    1 Defect or Non-conformance: any part of the Works not executed, provided or completed in
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    accordance with the Contract. For the avoidance of doubt and without limiting the generality
    of the expression the term shall be taken to include any item of Plant, material, goods or work
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    incorporated or used in the Works which does not or may not conform to the relevant quality
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    standards or pass the tests prescribed in or to be inferred from the Contract


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    2 Owner: The Ministry, Municipality, Department, Affairs, Agency, Authority, or individual for
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    whom the Project is being undertaken and to whom the handover of the final product will be
    made.

    3 QA & QC: Quality Assurance & Quality Control and this may be written as QA/QC.

    4 QA: Quality Assurance. Part of quality management focused on providing confidence that
    quality requirements will be fulfilled. QA involves a continuous evaluation of the adequacy
    and effectiveness of the overall Quality Management System in order to evaluate the
    deviation from established quality objectives.

    5 QC: Quality Control. Part of quality management focused on fulfilling quality requirements.
    The QC involves specific control points during design, fabrication or construction stages to
    check the fulfilling of design criteria, acceptance criteria (tolerance, etc.), performance criteria
    or functional criteria.
    QCS 2014 Section 01: General Page 3
    Part 23: Design & Supervision Consultant Quality Requirements

    6 QMS: Quality Management System. A set of interrelated or interacting processes, activities


    or tasks to direct Project resources to achieve established quality policy and objectives.

    7 Quality Management: Coordinated activities to direct and control an organization with


    regards to quality.

    23.2 DESIGN CONSULTANT QUALITY REQUIREMENTS

    23.2.1 Quality Responsibility and Duties

    1 The Design Consultant shall be responsible for setting up implementing and monitoring his
    own Contract Specific Quality Management System meeting the requirements of this part.

    2 The Design Consultant shall be responsible for quality auditing, monitoring and oversight of

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    any sub-consultants under their control.

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    3 The Design Consultant shall perform and or witness any examinations and tests necessary to

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    demonstrate conformance of the works to the requirements of the Contract and shall accept
    only works by the Contractor that so conform:

    4
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    The Design Consultant shall establish and maintain a system of records which shall provide
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    objectives evidence that the supervision Consultant is meeting the requirements of this
    specification and that the Contractors control and inspections are effective in meeting the
    minimum standards required under their contract. Records shall be made available to the
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    Engineer in accordance with the requirements stated herein or elsewhere in the contract.
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    5 The Design Consultant will be subject to monitoring through audit and surveillance by the
    Engineer. In both cases the Design Consultant shall promptly rectify any negative findings
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    with their Quality System rectify non-conformities and corrective actions found during audit
    and surveillance activities directed at them.
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    6 No part of the Quality system shall be used to preclude or otherwise negate the requirement
    of any part of the contract, or the obligation of the Design Consultant pursuant to the
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    Contract.
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    7 The Design Consultant shall appoint a suitably qualified, Quality Manager to verify that the
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    requirements of this specification are met. The proposed Quality Manager shall be subject to
    approval by the Engineer.

    23.2.2 Quality System Documentation

    1 The Design Consultant Quality system shall Include as a minimum the following

    (a) Quality Plan as detailed in 23.2.3 below


    (b) Procedures and work instruction: The Design Consultant Quality system must include
    all relevant technical procedures and other pertinent documentation to ensure that the
    design works are completed in accordance with the contract, with specific reference to
    the minimum requirements of standards reference in 23.1.2 above and including the
    mandatory procedures required by ISO 9001:2008.
    QCS 2014 Section 01: General Page 4
    Part 23: Design & Supervision Consultant Quality Requirements

    (c) Quality Records: In addition to (and including) quality records identified in the contract
    or other applicable codes, standards or procedures, the Design Consultant shall
    identify project quality records in compliance with the minimum requirements
    standards referenced in 23.1.2 above.
    (d) Reference and other related documents.

    2 Quality system documents shall be submitted to the owner for review, comment and approval
    within 30 days after contract award. In the event that comments are made on the contract
    Quality system documentation submitted for review and comment, the design consultant
    shall make adjustments, correction, amendment or alteration required. Such comment will be
    made on the premise that the adjustment, correction, amendment or alteration is within the
    scope of the contract and will not affect the contract conditions, specifications, guarantees,
    price or the like in anyway.

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    3 Adjustments, corrections, amendments or alterations made by the Design Consultant to the

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    contract quality system shall, after revision be resubmitted by the Design Consultant to the
    owner for review and approval.

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    23.2.3 Quality Plan

    1
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    Design Consultants are required to submit Quality Plan (addressing their design activities)
    qa
    which are specific (not generic) to the Contract, meeting as a minimum the requirements of
    the standards referenced in 23.1.2 above. This plan shall reference, or include other
    documentation which is relevant to the Contract. However as a stand-alone document, the
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    Quality Plan shall clearly indicate how the Quality process shall be applied to meet the
    requirements of the contract. Particular emphasis is to be placed on the following.
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    (a) Relevant extracts from the Corporate Quality Manual reference to specifications,
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    standards etc;
    (b) List of all procedures applicable to the project;
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    (c) QA/QC Organisation;


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    (d) Document Control;


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    (e) Inspection and Test;


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    (f) Specific work practices;


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    (g) List of all procedures applicable to the Consultants Project Quality System;
    (h) Audits (including internal and external Audits Plans);
    (i) Management Review;
    (j) Quality objectives, Key Performance Indicators (KPIs)
    (k) Allocation of resources;
    (l) Responsibilities and authority for all phases of work;
    (m) Control of Non-conformance, corrective and preventive actions.
    (n) Contract Changes;
    (o) Lessons learned and continual improvement;
    (p) Purchasing Process e.g. Sub Consultants.
    (q) Quality Records
    QCS 2014 Section 01: General Page 5
    Part 23: Design & Supervision Consultant Quality Requirements

    2 The Design Consultants Quality plan will make reference to and take into account applicable
    codes, standards, specifications, quality characteristics and regulatory requirements as
    necessary. It will identify the criteria by which the design and developments inputs and
    outputs should be accepted, and how, at what stage(s) and by whom, the outputs should be
    reviewed, verified and validated.

    3 The Design Consultants Quality Plan will also state the following.

    (a) How request for changes and development will be controlled to meet Contractual
    requirements;
    (b) Who is authorised to initiate a change request;
    (c) How changes will be reviewed in terms of their impact;
    (d) Who is authorised to approve or rejects changes;

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    (e) How the implementation of changes will be verified;

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    (f) When design and development reviews take place;

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    23.2.4 Construction Inspection and Test Requirements Specification

    1
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    The Design Consultant shall provide a specification addressing the complete inspection and
    testing regime related to their design output, taking into account the requirements of the
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    QCS. This shall be guiding document by which Supervision Consultants and Contractors will
    be held accountable for all on and off site tests and inspections to be performed. The
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    Inspection and Test Requirements Specifications must be sufficiently detailed to leave no


    questions regarding the number of samples required or types of tests to be made over and
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    above the requirements of the QCS and which standards must be complied with.
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    23.2.5 Design Consultant Verification of Sub Consultants


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    1 The Design Consultant is required to perform audits and verification activities at any sub
    consultants premises to gain assurance that the subcontracted product conforms to specified
    requirements.
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    23.2.6 Quality Records


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    1 In addition to (and including) quality records identified in the contract or other applicable
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    codes, standards or procedures, the Design Consultant shall determine project Quality
    records in compliance with requirements of ISO 9001:2008 and other relevant standards
    stated in contract documents and 23.1.2 above.

    2 The list of quality records generated during the life of the contract, and made available upon
    request for review by the Owner, shall be indexed by the Design Consultant in his Quality
    Plan.

    3 The Design Consultant shall maintain Registers for all incoming and outgoing documents.

    23.3 SUPERVISION CONSULTANT QUALITY REQUIREMENTS

    23.3.1 Quality Responsibilities and Duties

    1 The Supervision Consultant shall be responsible for setting up implementing and monitoring
    his own Contract Specific Quality Management System meeting the requirements of this part
    QCS 2014 Section 01: General Page 6
    Part 23: Design & Supervision Consultant Quality Requirements

    2 The Supervision Consultant shall be responsible for quality auditing, monitoring and oversight
    of themselves any consultants, contractors, sub-contractors (Including laboratories) under
    their control.

    3 The Supervision Consultant shall perform and/or witness any examinations and tests
    necessary to demonstrate conformance of the works to the requirements of the Contract and
    shall accept only works by the Contractor that comply with the specified requirements.

    4 The Supervision Consultant shall witness sampling and related testing performed on as well
    as testing performed in external Third Party Laboratories.

    5 The Supervision Consultant shall establish and maintain a system of records which shall
    provide objectives evidence that the supervision Consultant is meeting the requirements of
    this specification and that the Contractors control and inspections are effective in meeting the
    minimum standards required under their contract. Records shall be made available to the

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    Engineer in accordance with the requirements stated herein or elsewhere in the contract.

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    6 The Supervision Consultant will be subject to monitoring through audit and surveillance by
    the Engineer. In both cases the Supervision Consultant shall promptly rectify any negative
    findings with their quality system rectify non-conformities and corrective actions found during
    audit and surveillance activities directed at them.
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    7 The Supervision Consultants shall follow up on all findings (NCRs, CARs Observations)
    issued on the project to, or by the contractor or other entities under the contract.
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    8 No part of the quality system shall be used to preclude or otherwise negate the requirement
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    of any part of the contract, or the obligation of the Supervision Consultant pursuant to the
    Contract.
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    9 The Supervision Consultant is responsible for ensuring the contactors Work meets all
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    technical and quality requirements of the contract and shall keep continuous records of
    action taken and shall advise the Engineer in writing of significant alteration to construction or
    manufacturing techniques to ensure that specified requirements are met.
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    10 The Supervision Consultant shall conduct audit and surveillance activities to provide
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    evidence of the use and effectiveness of the Contractors quality system throughout the
    execution of the contract.
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    11 The Supervision Consultant will ensure that the Contractor has included the quality
    assurance requirements of the contract into subcontracts entered into by the Contractor.

    12 The Supervision Consultant shall provide an effective audit and surveillance process for
    works performed by a Contractors Subcontractors..

    13 The Supervision Consultant shall verify that the Contractors Project Quality Plan, Inspection
    and Test Plans and other such quality documentation includes or references the Quality
    Plans, and Inspection and Test Plans of subcontractors and vice versa. All of these
    documents must be reviewed and approved by the Supervision Consultant.

    14 The Supervision Consultant shall hold contract specific QA/QC meetings chaired by the
    Consultant on a monthly basis throughout the duration of the Work. Topics to be addressed
    at the site quality meeting shall include, but shall not be limited too:
    QCS 2014 Section 01: General Page 7
    Part 23: Design & Supervision Consultant Quality Requirements

    (a) Reviewing of the previous months Quality


    (b) Current Performance of the activities
    (c) Providing 4 week look ahead of planned activities
    (d) Non Conformance of activities
    (e) Key performance indicators
    (f) Audit schedule
    (g) Status of inspection of test plans and method statements
    (h) Quality Training
    (i) Contractors Project quality plan and quality control plans review and on-going
    effectiveness

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    15 The Supervision Consultant shall be responsible for providing a Monthly Quality Report

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    template, meeting the Owner requirements, to the Contractor and reviewing the completed
    reports submitted by the Contractor.

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    16 The Supervision Consultant shall be responsible for completing any QA/QC Questionnaires
    or Reports required by the Owner.
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    17 The Supervision Consultant shall appoint a suitably qualified, full time, Quality Manager to
    verify that the requirements of this specification are met. The proposed Quality Manager shall
    be subject to approval by the Owner.
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    23.3.2 Quality System Documentation


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    1 The Supervision Consultant Quality System shall include as a minimum the following
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    elements.
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    (a) Quality Plan as detailed in 23.2.3 below


    (b) Procedures and work instruction: The Supervision Consultant Quality system must
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    include all relevant technical procedures and other pertinent documentation to ensure
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    that the design works are completed in accordance with the contract, with specific
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    reference to the minimum requirements of standards reference in 23.1.2 above


    including the mandatory procedure required by ISO 9001:2008
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    (c) Quality Records: In addition to (and including) quality records identified in the contract
    or other applicable codes, standards or procedures, the Supervision Consultant shall
    identify project quality records in compliance with the minimum requirements
    standards referenced in 23.1.2 above
    (d) Reference and other related documents

    2 These Quality system documents shall be submitted to the Owner for review, comment and
    approval within 30 days after contract award. In the event that comments are made on the
    contract quality system documentation submitted for review and comment, the Supervision
    Consultant shall make adjustments, correction, amendment or alteration required. Such
    comment will be made on the premise that the adjustment, correction, amendment or
    alteration is within the scope of the contract and will not affect the contract conditions,
    specifications, guarantees, price or the like in anyway.
    QCS 2014 Section 01: General Page 8
    Part 23: Design & Supervision Consultant Quality Requirements

    3 Adjustments, corrections, amendments or alterations made by the Supervision Consultant to


    the contract quality system shall, after revision be resubmitted by the Supervision Consultant
    to the Owner for review and approval.

    23.3.3 Quality Plan

    1 Supervision Consultants are required to submit Quality Plans (addressing their supervision
    activities) which are specific (not generic) to the Contract, meeting as a minimum the
    requirements of the standards referenced in 23.1.2 above. This plan shall reference, or
    include other documentation which is relevant to the Contract. However as a stand-alone
    document, the Quality Plan shall clearly indicate how the Quality process shall be applied to
    meet the requirements of the contract. Particular emphasis is to be placed on the following
    requirements of ISO 9001:2008.

    (a) Relevant extracts from the Corporate Quality Manual reference to specifications,

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    standards etc;

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    (b) List of all procedures applicable to the project;

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    (c) QA/QC Organisation;
    (d) Document Control;
    (e) Inspection and Test; ta
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    (f) Specific work practices;
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    (g) List of all procedures applicable to the Consultants Project Quality System;
    (h) Audits (including internal and external Audits Plans);
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    (i) Management Review;


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    (j) Quality objectives, Key Performance Indicators (KPIs)


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    (k) Allocation of resources;


    (l) Responsibilities and authority for all phases of work;
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    (m) Control of Non-conformance, corrective and preventive actions.


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    (n) Contract Changes;


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    (o) Lessons learned and continual improvement;


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    (p) Purchasing Process e.g. Sub Consultants.


    (q) Quality Records;

    2 The Supervision Consultants Quality Plan will make reference to applicable codes,
    standards, specifications, quality characteristics and regulatory requirements as appropriate.
    It will identify the criteria by which inputs and outputs should be accepted, and how, at what
    stage(s), and by whom, the outputs should reviewed, verified and validated.

    3 The Supervision Consultants Quality Plan will also address the following:

    (a) How request for changes and development will be controlled to meet Contractual
    requirements;
    (b) Who is authorised to initiate a change request;
    (c) How changes will be reviewed in terms of their impact;
    QCS 2014 Section 01: General Page 9
    Part 23: Design & Supervision Consultant Quality Requirements

    (d) Who is authorised to approve or reject changes;


    (e) How the implementation of changes will be verified;
    (f) When reviews take place;
    (g) Redline and As-Built process;

    4 Where design is required by the Contractors contract, the Supervision Consultant


    responsibilities for the Contractors design work shall be as defined under the contract,
    however not withstanding this the Supervision Consultant shall responsible for auditing this
    function of the Contractors quality system.

    23.3.4 Inspection and Test Plans (ITPS)

    1 As per the requirements of QCS, the Supervision Consultants shall require the Contractor to

    .
    submit Inspection and Test Plans to the Supervision Consultant a minimum 30 days prior to

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    the programmed work start date covered by each Inspection and Test Plan.

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    2 The Minimum requirements for the Contractors Inspection and Test Plan are defined in QCS,
    and the supervision Consultant is responsible for ensuring the Contractors Inspection and
    Test Plan as a minimum meet these requirements or the recommendations of the Design
    Consultants.
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    3 The Supervision Consultants shall ensure that the Contactors Inspect and Test Plan
    adequately cover any Inspections and test points (Hold/Witness/Surveillance/Record Review)
    as

    required for the Supervision Consultant to ensure that the works are completed in
    accordance with the contract.
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    4 Where the Design Consultant for the Contract has detailed specific specifications or
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    inspection and test requirements, the supervision Consultants shall ensure these have been
    addressed within the Contractors Inspect and Test Plan. Where a discrepancy exits between
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    Inspections and Test requirements of the Design Consultant and the requirements of QCS,
    the more stringent requirements shall be adopted.
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    5 The Supervision Consultant is responsible for reviewing and approving all Inspection and
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    Test Plans and other such documentation submitted by the Contractor and returning to the
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    Contractor within two weeks of their receipt unless otherwise agreed.


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    6 The Supervision Consultant shall ensure that inspection of processes, materials, good,
    services and subcontracted works are described in the Inspection and Test plan submitted by
    the Contractor.

    23.3.5 Technical Procedures, Work Instructions and Method Statements

    1 The Supervision Consultants shall verify through audit and surveillance that the Contractors
    quality system includes all relevant Technical Procedures, Work Instructions Method
    Statements and Inspection and Test Plans to ensure that the Works are completed in
    accordance with the contract. These shall be submitted by the contractor in accordance with
    the submission schedule agreed with the Supervision Consultant including those which form
    part of the Contractors Quality System.
    QCS 2014 Section 01: General Page 10
    Part 23: Design & Supervision Consultant Quality Requirements

    2 The Supervision Consultants own Quality system likewise shall include relevant Technical
    Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure
    that the works are completed in accordance with the contract with specific reference to the
    development and implementation of Quality Procedures specified in ISO 9001:2008. These
    shall be submitted to the Owner by the Supervision Consultant in accordance with the
    submission schedule agreed with the Owner including those which form part of the
    Supervision Consultants corporate quality system.

    23.3.6 Monitoring by Supervision Consultants

    1 Surveillance by the Supervision Consultants will include a variety of typical activities:

    (a) review of contractor documentations


    (b) audits of Contractor

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    (c) attendance at Hold/Witness/Surveillance Points

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    (d) Record Review

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    (e) Visits to Contractors off site works etc
    (f) Factory Acceptance Tests

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    With the exception of visits, these activities will be announced to the Contractors in advance.
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    The Supervision Consultants shall give reasonable notice to the Contractor who is required to
    make or arrange to be made available all facilities, documentations records and personnel,
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    including those of any subcontractors, which are required for any surveillance activity to be
    taken.
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    3 The Supervision Consultants shall advise the Contractor in writing of any deficiency or
    deviation in the contract quality system which comes to the Supervision Consultants
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    attention as a result of surveillance activities. The Contractor shall be required to rectify the
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    system within as short a period as may be reasonably expected considering the deficiency or
    deviation. The Supervision Consultant may direct the Contractor in writing to stop the
    operation and immediately carry out any corrective action, and the Contractor must comply
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    with such direction at his cost. All deficiencies uncovered shall be documented with a Non-
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    Conformance Report or Corrective Action Request as appropriate (Refer to QCS, Section 2


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    for a NCR template).


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    23.3.7 Review of Contractor Quality Documentation

    1 All audits of the Contractor shall be conducted in accordance with a schedule establish by the
    Supervision Consultant. These audits are to be performed in accordance with formal
    procedures by trained and qualified auditors.

    2 The types of audit to be conducted are as follow:

    (a) Systems Audit: One System audit will undertaken at or before the start of work on the
    contract deliverables (the specified Works). The audit will be conducted against the
    requirements of ISO9001:2008
    (b) Compliance Audits: A number of compliance audits will be conducted at defined
    milestones in the contract deliverable period. The scope of a compliance audit shall be
    set by the supervision Consultant to suit the timing of activities, and the findings of the
    system audit. For example, the scope of a compliance audit could cover any of the
    following:
    QCS 2014 Section 01: General Page 11
    Part 23: Design & Supervision Consultant Quality Requirements

    (i) the complete requirements of the standards and the contract,


    (ii) specific elements of the standard
    (iii) specific clauses of the contract
    (iv) the whole or a part of a single end-to-end process.

    (c) Product audit: This is a Quality audit of particular deliverable products to check their
    compliance with specified requirements. Such audits should include performance
    testing where appropriate.

    3 The Audit Notification shall also be copies to the Owner for information and they may attend
    these audits as an observes. The Audit Reports shall be submitted to the Owner within 7
    days.

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    23.3.8 Inspection Responsibilities

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    1 For all work the Supervision Consultant shall:

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    (a) Review and check that the contractors Method statement and Inspection & Test Plans

    (b) ta
    are in accordance with the contract Surveillance Points.
    Inspect all works to verify Contractors compliance with the Method Statements,
    qa
    Inspections and Test Plans, Construction Drawings and Specifications.
    (c) Verify that notices of nonconformity have been properly actioned.
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    (d) Oversee the sampling and testing of materials to ensure conformity to the
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    specifications and the contract.


    (e) Review all test results and verify that they are in conformity with the Specifications and
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    the Contract.
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    (f) Maintain comprehensive records to verify the above.

    23.3.9 Inspections and Test Surveillance Points


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    1 The Supervision Consultant shall nominate his own surveillance points to observe the
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    Contractors and Subcontractors activities and maintain evidence of such surveillance.


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    (a) Hold Points Specific critical task in procurement, manufacturing, inspection and
    testing for which the Supervision Consultant is pre-notified, in advance of the task and
    for which no further work is carried out until the supervision Consultant has verified and
    confirmed conformity by signing off the relevant Records Forms
    (b) Witness Points- Specific critical task in procurement, manufacturing, inspection and
    testing for which the Supervision Consultant is pre-notified in advance of the task and
    for which the Supervision Consultant may elect to attend or waive. When attended, the
    Supervision Consultant shall confirm conformity by signing off the relevant Record
    Forms. When then Supervision Consultant waives his right to inspect, it should be
    recorded as such on the appropriate Record Forms.
    (c) Surveillance points- Any procurement, manufacturing, inspection and testing task, so
    identified on the Inspection and Test Plan, performed on a random basis, without
    notification by the supervision Consultant.
    (d) Record Review- When specified this point requires the Supervision Consultant to
    Collect and review for approval the contractor Inspection & Rest Records.
    QCS 2014 Section 01: General Page 12
    Part 23: Design & Supervision Consultant Quality Requirements

    23.3.10 Visits

    1 The Supervision Consultants is empowered to visit any of the Contractors or Subcontractors


    work sites for any purpose at reasonable times. The Contractors will assist with such visits
    and make available those records and personnel necessary to satisfy the supervision
    Consultants requirements. Such visits may include surveillance points identified by the
    Contractor and Subcontractors. These visits may include works situated outside of Qatar.

    23.3.11 Supervision Consultant Verification

    1 The Supervision Consultant has the right to perform verification activities at the Contractors
    and the Subcontractors premises (including the construction site) to gain assurance that the
    subcontracted product conforms to specified requirements.

    23.3.12 Interfacing

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    1 The Supervision Consultant is responsible for ensuring that the interfaces between the

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    contract works and different packages of work and different Contracting entities are managed
    appropriately and that technical integrity and configuration control is maintained.

    23.3.13 Punch Lists


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    1 The Supervision Consultants shall be responsible to ensure that the Contractor prepares
    punch lists at appropriate inspection and acceptance stages to record the outstanding work.
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    Defects identified during the punch list walk downs will also require NCRs to be raised, other
    than for minor defects. The Owner or its nominee may at any time add pending items or
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    defects or Nonconformances to Punch Lists.


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    23.3.14 Protection of the Works


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    1 The Supervision Consultant has the responsibility to ensure that the Contractor is taking
    necessary precautions for the protection of works before the Initial/Final
    Acceptance/Handover to owner or its nominee.
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    23.3.15 Quality Records


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    1 In addition to (and including) quality records identified in the contract or other applicable
    m

    codes, standards or procedures, the Supervision Consultant shall determine project Quality
    records in compliance with requirements of ISO 9001:2008 and other relevant standards
    stated in contract documents and 23.1.2 above.

    2 The list of quality records generated during the life of the contract, and made available upon
    request for review by the Owner, shall be indexed by the Supervision Consultant in his
    Quality Plan.

    3 The Supervision Consultant shall maintain Registers for all incoming and outgoing
    documents.

    END OF PART
    QCS 2014 Section 01: General Page 1
    Part 24: Construction Dewatering

    24 CONSTRUCTION DEWATERING 2
    24.1 GENERAL 2
    24.1.1 Scope 2
    24.2 REQUIREMENTS 2
    24.2.1 Current Procedure Requirements 2
    24.2.2 Relevant Qatari Laws and Regulations 2
    24.2.3 EIA Requirements 3
    24.2.4 Air Quality Standards 3
    24.2.5 Noise Standards 3
    24.2.6 Discharge to Surface and Groundwater Network Standards 3
    24.2.7 Environmental Impact Assessment (EIA) 3
    24.2.8 Geotechnical and Geo-Environmental Study Requirements 3
    24.2.9 Existing Groundwater Monitoring Documents 4

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    24.2.10 Risk Assessment of Construction Dewatering 4

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    24.2.11 Dewatering Monitoring Plan 5
    24.2.12 Training Requirements 6

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    24.3 DEWATERING TECHNIQUES 7
    24.3.1 Construction Dewatering Methods Guide Lines 7
    24.3.2
    24.3.3
    Sump Pits
    Well System ta 8
    8
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    24.3.4 Deep Wells 8
    24.3.5 Ditches/ French Drains 9
    24.3.6 Cut-Off Excavation Barriers 9
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    24.3.7 Dewatering Effluent Treatment 9


    24.3.8 Settlement Tank 9
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    24.3.9 Settlement Tank Types 9


    24.3.10 Tank Size 10
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    24.4 OTHER TREATMENT 10


    24.4.1 Silt and Fine Grained Soils 10
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    24.4.2 Contamination of Groundwater 12


    24.5 DISPOSAL OPTIONS 12
    24.6 DISCHARGE TO SEA 13
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    24.6.1 Discharge to Sea via Surface and Groundwater Network 13


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    24.6.2 Direct Discharge to Sea 15


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    24.6.3 Discharge to Lagoons: 16


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    24.6.4 Discharge by injection to deep groundwater aquifer (Deep well injection) 17


    24.6.5 Groundwater Recycle & Reuse Onsite 18
    24.6.6 Integrated Management of Construction Dewatering 19
    24.6.7 Construction Environmental Management Plan (CEMP) 19
    24.6.8 Monitoring Plan 19
    24.6.9 Training Plan 20
    24.6.10 Odour Control 20
    24.6.11 Health & Safety Considerations 20
    24.6.12 Site Investigation 21
    24.6.13 Design Considerations 21
    24.6.14 Housekeeping Considerations 21

    Appendices 22
    QCS 2014 Section 01: General Page 2
    Part 24: Construction Dewatering

    24 CONSTRUCTION DEWATERING

    24.1 GENERAL

    24.1.1 Scope

    1 This Part specifies the general procedures and requirements for construction dewatering.

    2 It should be noted that legislative requirements, standards and requirements detailed in this
    Part are minimum standards, and methods should be employed with the intent to continually
    improve on these standards.

    3 Related Parts and Sections are as follows:

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    Section 8 Earthworks

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    Section 9 Mechanical and Electrical Equipment

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    24.2 REQUIREMENTS

    24.2.1 Current Procedure Requirements


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    1 There are four types of construction dewatering disposal options that require licensing in
    Qatar, as follows:
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    (a) Discharge to the Sea via surface and groundwater network; the licensing authority
    should be ASHGHAL and MOE.
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    (b) Direct discharge to the Sea; if the discharge is pumped directly to the sea, then the
    Ministry of Environment (MOE) should be the licensing authority.
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    (i) Discharge to Lagoon totally covered with geotextile from all sides. This method
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    of disposal requires a license from MOE.


    (ii) Discharge to Lagoon not covered. This method of disposal requires a license
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    from MOE.
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    (c) Discharge through Deep Well Injection. This method of disposal requires a license
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    from MOE.
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    24.2.2 Relevant Qatari Laws and Regulations

    1 The list of parameters required by MoE for dewatering permit is included in Appendix A
    together with Annex 4 of Law 30 of 2002 which specifies the limits for the discharged water
    into the marine environment (refer to Appendix A). The annex controls the parameters of
    pollutants in the water disposed to the marine environment whether via the Surface and
    Groundwater Network, or direct discharge to the sea.

    2 If the construction dewatering effluent is discharged to foul network, the discharging party is
    liable to having committed a criminal offence.

    3 In the case of illegal discharge to Surface and Groundwater Network, the discharging party
    will be subjected to legal actions taken by the licensing authorities.
    QCS 2014 Section 01: General Page 3
    Part 24: Construction Dewatering

    24.2.3 EIA Requirements

    1 Environmental approvals from the MoE as per Article 7 of the Law No. 30 of 2002.

    24.2.4 Air Quality Standards

    1 The air quality standards are controlled by the Law No. 30 of 2002 under Annex (3/First).The
    standards applicable to dewatering activities may include the following:

    2 Maximum limits (of air pollutants) allowed for emissions from the movable sources; and
    Ambient air quality standards.

    24.2.5 Noise Standards

    1 The noise levels are also controlled by the Qatari Legislation under Law No. 30 of 2002

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    Annex (2/Fifth).

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    24.2.6 Discharge to Surface and Groundwater Network Standards

    1 Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) Of

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    2002. Annex No. (4) Criteria and Specifications of the Hazardous Materials when disposed
    of in the Water Environments (MoE regulations).
    qa
    24.2.7 Environmental Impact Assessment (EIA)
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    1 For projects requiring an EIA at the design stage, the EIA should be carefully reviewed by
    the Design Consultant / Contractor. The EIA should be forwarded to MoE for their approval
    se

    and for issuing the relevant Environmental Permit.


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    2 Where available, the EIA will contain details of geotechnical surveys including groundwater,
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    adopted from the previously mentioned report.

    3 Although the EIA may not directly contribute to the construction dewatering design, it will
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    document possible contamination in the area and environmental constraints, and should
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    therefore be considered when preparing construction dewatering application papers. Existing


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    contamination, or potential for contamination, should be carefully considered and must be


    taken into account when dewatered groundwater is tested for compliance.
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    4 To ensure that dewatering systems are designed to maximise environmental protection and
    to assist in expediting license approval processes, the above investigations shall be taken
    into consideration as early in the project as possible and included when applying for the
    discharge permit.

    24.2.8 Geotechnical and Geo-Environmental Study Requirements

    1 After the awarding of the Contract to the Contractor and prior to obtaining the discharge
    permit, if required by the Contract or requested by the Engineer, the Contractor shall carry
    out a geotechnical and geo-environmental investigations in order to confirm the geotechnical
    and environmental conditions on site and groundwater levels.
    QCS 2014 Section 01: General Page 4
    Part 24: Construction Dewatering

    2 The geotechnical and geo-environmental study must as a minimum identify soil types,
    permeability, groundwater hydrology, and the required drawdown for the construction
    activities. This study is required if the area is suspected for contamination or if the EIA at the
    design stage has indicated the existence of contamination.

    3 The output of the geotechnical and geo-environmental study should include as a minimum
    the following items:
    (a) Time required for construction dewatering.
    (b) Flow rate of the dewatering discharge.
    (c) Required drawdown.
    (d) Method of construction dewatering based on all of the above findings.

    4 To assist in the approval process all of the above information must be provided in the

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    application for discharge.

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    5 It is important to note that the requirements of the Geotechnical and Geo-environmental
    study are completely subject to project settings, type of contamination, and MoEs specific
    requirements of each project.

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    24.2.9 Existing Groundwater Monitoring Documents

    1 It is the Contractors responsibility to ensure he has been providing the latest existing
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    groundwater level information from Ashghal and the MoE. This information should be used
    by the Contractor to assist in determining the current site conditions.
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    2 All groundwater information gathered during studies by the Contractor, are to be submitted to
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    Ashghal for reference and inclusion in the country database. The collection of this
    information is paramount to the continuous improvement of government information
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    databases.

    24.2.10 Risk Assessment of Construction Dewatering


    it o

    1 It is important to note that risks are site specific and depend on the intent of the Contractor.
    et

    The Contractor is responsible for developing, implementing and managing a Risk


    m

    Management System and conducting a Risk Assessment in terms of dewatering activities


    and otherwise onsite.

    2 This Risk Management System and Risk Assessment shall be the submitted to the Engineer
    for the approval within the 30 days of the contract award.

    3 Risk assessment in this instance can be defined as the identification and characterisation of
    the nature of existing and potential adverse effects to humans and the environment resulting
    from dewatering activities employed on site.

    4 Risk is a function of the probability of an event occurring and the degree of damage that
    would result should it happen.

    5 Details and information gathered during the concept design and associated site studies
    (geotechnical, groundwater & environmental) are needed to assess the risks associated with
    the proposed activities. The assessment allows significant risks to be identified so that they
    can be targeted for action.
    QCS 2014 Section 01: General Page 5
    Part 24: Construction Dewatering

    6 The initial risk assessment needs to also be regularly reviewed and will become an integral
    part of the Construction Environmental Management Plan. This includes a review of existing
    risks and the identification of new risks detected through the surveillance or the monitoring
    program.

    7 To conduct the Risk Assessment the Contractor should undertake the following key steps:
    (a) Information gathering:

    A risk assessment requires information about site conditions.


    (b) Risk identification:

    Hazard identification involves the identification of risks/hazards that could lead to an


    adverse effect on the receiving environment and/or health & safety.

    .
    (c) Risk analysis:

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    Risk analysis considers the likelihood of the risk being realised.

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    (d) Consequence analysis:

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    Consequence analysis determines the effect on the environment and health & safety
    should a risk be realised.
    qa
    8 The overall risk is a function of the likelihood of the activity or event causing environmental
    as

    harm or impacting on health & safety and the consequence should that risk be realised.
    se

    9 The risks are then ranked according to their magnitude and mitigation strategies developed.

    10 The objective of this process is to identify and rank all potential risks that may arise from the
    er

    dewatering of the construction site and then reduce risks to acceptable levels by
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    implementing a suitable method of dewatering and/or action plan.

    11 Risks generally associated with dewatering activities onsite include but not limited to the
    o

    following:
    it

    (a) Soil and slope stability and soil erosion due to dewatering activities.
    et

    (b) Soil contamination. Whether contamination exists in the project area prior to
    m

    commencement of construction or is caused by dewatering activities.


    (c) Change of groundwater properties due to dewatering practices.
    (d) Excessive abstraction (dewatering) of groundwater which affects nearby groundwater
    related activities.
    (e) Health and safety related issues.
    (f) Risks associated with impacts of dewatering activities on surrounding environment
    and sensitive receptors.
    (g) Risks associated with failure of dewatering system and/or disposal methods.

    24.2.11 Dewatering Monitoring Plan

    1 When dewatering activities are included within the project site, the Contractor shall prepare a
    Dewatering Monitoring Plan as detailed below.
    QCS 2014 Section 01: General Page 6
    Part 24: Construction Dewatering

    2 The Dewatering Monitoring Plan shall be submitted to the Engineer for approval within 30
    days of contract award.

    3 The monitoring plan will assist the licensing authority, as well as the Contractor, in keeping
    track of dewatering activities onsite, and identify corrective actions to be carried out.

    4 The monitoring plan can also assist in identifying liability issues concerned with reported
    dewatering problems and accidents.

    5 Outline and components of monitoring plan are as follow:


    (a) Identification of opportunities to reuse the dewatering effluent onsite in order to reduce
    the amount of disposed effluent.
    (b) Dewatering techniques being employed on site

    .
    (c) Disposal methods employed on-site and relevant monitoring plan to ensure

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    compliance with discharge limits.

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    (d) Copy of discharge limits.
    (e) Roles and responsibilities of the Environmental Advisor on site.

    6 ta
    Roles and responsibilities have to be clearly defined when designing a dewatering system.
    qa
    These roles and responsibilities are to be submitted as an essential element to satisfy the
    Construction Environmental Management Plan requirements when applying for the
    dewatering effluent discharge permit.
    as

    7 Refer to Appendix B for an example of inspection sheet for the dewatering process.
    se

    24.2.12 Training Requirements


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    1 The Contractor shall prepare a Construction Dewatering Training Plan submitted along with
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    the necessary documentation for a discharge permit.


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    2 The construction dewatering training plan shall be submitted to the Engineer for approval
    it

    within 30 days of contract award.


    et

    3 The training plan will assist the licensing authority in evaluating the level of knowledge
    m

    passed on to the Contractors staff, and is therefore an indirect indication on how well the
    dewatering process is being executed. The components of the submitted training plan are
    detailed below.

    4 The integration of construction dewatering training into the Training Plan of the Contractor is
    essential to introduce all staff to construction dewatering related information.

    5 It is recommended that information on dewatering equipment and related emergencies are


    included in the training provided to staff entering or working on the site.

    6 The training for all staff does not have to be comprehensive; however, it should include basic
    items such as:
    (a) Brief explanation of the construction dewatering purpose
    (b) Introduction to the dewatering equipment. Inclusion of photos in the training
    presentation.
    QCS 2014 Section 01: General Page 7
    Part 24: Construction Dewatering

    (c) Health and safety related concerns, education on related emergencies, and contact
    information of person in charge of dewatering to be provided in the presentation.

    24.3 DEWATERING TECHNIQUES

    24.3.1 Construction Dewatering Methods Guide Lines

    1 The design of effective construction dewatering methods should be based on a number of


    information sources:
    (a) Geotechnical and groundwater site investigations undertaken at the commencement
    of any project;
    (b) Information provided by any geotechnical study undertaken during the concept design
    stage[if applicable];

    .
    (c) Groundwater information sourced from relevant authorities; and,

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    (d) A site risk assessments.

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    2 The Contractors choice of dewatering method will depend primarily on the soil type and
    permeability and the amount of groundwater to be removed. Whilst the Contractor will be

    ta
    trying to find the most cost effective method of dewatering (based on the geotechnical report)
    qa
    he shall implement the most effective dewatering method which minimises environmental
    damage, protects the health & safety of on-site personnel and meets all legislative discharge
    limits.
    as

    3 It is important to note that if contamination exists in the area all precautions need to be
    se

    implemented. Contamination will be dealt with in coordination with MoE by safe disposal in
    designated areas as per the Environmental Law number 30 for 2002.
    er

    4 The figure below demonstrates the range of common dewatering techniques, whilst
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    accounting for soil permeability and drawdown.


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    et
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    Range of Application of Pumped Well Groundwater Control Techniques


    ** Source: Preene, M. Roberts, T. Powrie, W. Dyer, M R (2000)- Groundwater Control Design &
    Practice (CIRIA C515), London, CIRIA.
    QCS 2014 Section 01: General Page 8
    Part 24: Construction Dewatering

    5 As seen in the above figure, the choice of dewatering method depends on the required
    drawdown and permeability. The drawdown is determined during the design stage of
    structures and the groundwater investigation stage at the start of the project and the
    permeability is tested during the geotechnical investigation stage.

    6 After the drawdown is determined, the Contractor shall choose the method of dewatering
    based on the permeability of soil. The method can vary during the stages of the project
    depending on the required drawdown. The shaded areas near the methods boundaries
    indicate that the choices can overlap, and then the Contractor can decide between the two
    (or more) options.

    7 Filtering and filling materials of aggregate is required by most dewatering methods.


    Therefore when required, aggregates to be used shall be free draining, washed and free of
    debris (organic or non-organic). Preference is for a single sized aggregate (less than 10%

    .
    fines).

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    8 Whilst the range of dewatering practices varies across sites depending on their size,

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    construction depth and site conditions, the most commonly used methods of dewatering in
    Qatar are indicated below. Each methods use depends on the requirements and stage of
    project.
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    24.3.2 Sump Pits

    1 The Sump Pit method is the simplest form of dewatering system on a construction site.
    as

    Sump pits are generally utilised as a quick, least cost, solution and can be seen to be used
    at the start of projects as the excavation stage commences. Provided with an aggregate
    se

    lining, as per O&M requirements, sump pits can be an effective means of filtering
    groundwater, unless the groundwater has come into contact with silt and/or limestone, which
    er

    usually results in reported high turbidity.


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    2 If soil has silty characteristics; it is recommended that proper installation of geotextile and
    aggregates in sump pits be implemented in order to improve the quality of dewatering
    o

    effluent and significantly decrease turbidity.


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    24.3.3 Well System


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    1 The most common practice of dewatering used in Qatar is the implementation of a Well
    System. Wells are systematically drilled around the construction area and submersible
    pumps placed into these wells. This practice appears to work effectively for many projects,
    especially those building projects that require excavations for deep basements.

    24.3.4 Deep Wells

    1 Deep wells are rarely used in Qatar. Deep wells are usually equipped with filter packs &
    submersible pumps, and are operated using a control cabin.

    2 Although not found to be present in Qatar at present, deep wells have unlimited drawdown,
    they require a minimum spacing of 10 meters, and have far greater efficiency.
    QCS 2014 Section 01: General Page 9
    Part 24: Construction Dewatering

    24.3.5 Ditches/ French Drains

    1 Ditches and French drains (commonly known as trenches in construction projects in Qatar)
    are also used on Qatars construction sites. The ditches are formed in a pre-planned
    manner, allowing groundwater flow to surface in the deeper level trenches. Perforated pipes
    are then placed in the trenches, and groundwater extracted through these pipelines to be
    filtered. These trenches were particularly common in infrastructure network projects.

    2 Graded aggregates and geotextile layer to be used when laying out the pipelines.

    24.3.6 Cut-Off Excavation Barriers

    1 Cut Off barriers are designed to limit and/or control groundwater entering the construction
    site from a neighbouring property. An assessment of groundwater infiltration is required to
    determine to what extent barriers are required and how they are constructed.

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    2 Commonly used excavation barriers in Qatar include structural concrete walls and secant

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    piles. Both techniques are applicable to most types of soil and provide slope stability for
    deep excavated areas.

    24.3.7 Dewatering Effluent Treatment


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    24.3.8 Settlement Tank
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    1 The settlement tank is the most common and most effective methods of treatment in Qatar.
    The settlement tank is primarily used to maximise the distance that the effluent has to travel
    se

    prior to reaching the discharge point, and therefore increasing the settlement efficiency.
    er

    2 All projects in Qatar which apply for a discharge permit are obligated to provide a settlement
    tank.
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    3 When choosing the settlement tank, the choice should be based on the following factors:
    o

    (a) The type of soil to be dewatered.


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    (b) Flow rate quantity and frequency.


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    (c) Possible peak factors flows.


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    (d) Retention time required for solids to settle. This will also be based on the soil type.

    24.3.9 Settlement Tank Types

    1 The common types of weir tanks used are Regular tank and V-notch tanks (30, 60, and
    90). The V-notch tanks serve to accelerate the passing of the effluent through the tank.

    2 For safety purposes, it is recommended that tanks be suitably covered with a top cover or
    specific lid, to ensure unauthorised access is not permitted.

    3 It is important to note that sometimes these tanks are used onsite as a discharge tanks.
    Therefore, it is important that tanks are used as settlement tanks and be marked clearly as
    such.
    QCS 2014 Section 01: General Page 10
    Part 24: Construction Dewatering

    24.3.10 Tank Size

    1 In order to make a decision on the tank size, the volume of tank are to be estimated as per
    the below equations.

    2 The volumes calculated depend primarily on the retention time of water in the tank, and the
    flow rate of discharge.

    Equation
    3
    V: Volume (m )
    3
    Tank volume V=Qt Q: Expected flow rate (m /hour)
    t: retention period (hour)

    d: depth (m)

    .
    3

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    The tank's depth d = V/A V: volume(m )

    .l.
    2
    A: surface area(m )

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    3 It is important to note that these equations are to be used as a guide only, but do provide a
    basis for calculating the minimum tank size required based on the flow rate provided by the
    Contractor.
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    4 For fine grained type of soils, it is preferred to have secondary methods of treatment as
    detailed below.
    as

    24.4 OTHER TREATMENT


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    24.4.1 Silt and Fine Grained Soils


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    1 For the removal of silt and fine grained suspended particles, the following inexpensive
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    methods can be effectively applied:


    (a) Dewatering Tank:
    it o

    a dewatering tank can remove sediment (sand, silt, and visible oil). The dewatering
    et

    tank is equipped with a fabric filter. The flow passes through the filter before being
    discharged at the bottom end of the tank. The tank can be used in addition to the weir
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    tank or any other treatment method. It is portable, inexpensive and many types of filter
    clothes can be used.

    Yet, the dewatering tanks should be subjected to periodic cleaning based on the visual
    inspection or reduced flow, through lifting the sand and silt from the tank.
    (b) Gravity Bag Filter:

    (Also known as dewatering bag) is made of geotextile fabric that can filter out silt and
    fine grained soil particles. This filter is easy to install, inexpensive, and becomes more
    effective as sediment builds up inside the bag. The type of bag should be selected
    based on the flow rates of discharge and permeability of soil.

    This method is to be used as a secondary treatment for groundwater. It requires


    continuous monitoring to avoid hose failure, particularly if sediment builds up in a
    manner that interferes with the acquisition of a reasonable flow rate discharge.
    QCS 2014 Section 01: General Page 11
    Part 24: Construction Dewatering

    The Gravity Bag Filter does not require cleaning, as it is a disposable filter. The filter is
    to be disposed of in accordance with the waste management guidelines of the project.
    The filter is to be replaced when it starts passing solids, or blocks the passing of water
    at a rate that is adequate.
    (c) Slurry Water

    The drilling [slurry] muds containing substantial quantities of organic liquids and
    water-soluble salts are treated to render them environmentally acceptable for
    disposal (C M Wilwerding 1989)

    Slurry water occurrence is common during dewatering processes in Qatar. While there
    is filtration equipment and water treatment technology available to treat slurry water,
    these are best used in countries with a different climate to that of Qatars.

    .
    2 The best option for treating slurry by filtration is using a Centrifugal Filter. However, as

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    previously mentioned, this is not a preferable to be used in Qatar as slurry can be dried
    easily in a more environmentally friendly manner.

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    3 It is also important to note that even when treatment equipment is used, the resulting silt will

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    have to be disposed at a licensed landfill, along with having to dispose of the equipment at
    its end of service life.
    qa
    4 If the silt contains hazardous material, then a license should be issued from MoE as per the
    procedures detailed in Annex (7.2) of the Qatari Law of Environment (Copy of the
    as

    procedures together with the form of application is provided in Appendix (C)). And if the silt
    has no hazardous materials then the license shall be issued from the concerned
    se

    Municipality.
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    5 To eliminate the issues with incompatible equipment and hot climates, it is recommended
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    that treatment methods be designed to manage the slurry either onsite by drying the first
    instance before transfer to landfill, or by transfer to the landfill directly.
    o

    6 The conventional drying process comprises laying out of slurry mud on an air permeable
    it

    drying bed lined with suitable material.


    et

    7 The drying process must commit to the following environmental considerations:


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    (a) Amount of slurry generated must not exceed the capacity of the spreading system.
    (b) Drying process must not impose nuisance or emit odor.
    (c) Drying process must not impose health and safety risks.

    8 The choice of drying process, whether by using a centrifuge machine or a drying lagoon is
    subject to project settings and expected amount of slurry to be generated.

    9 The slurry handling process is to be submitted with the dewatering permit application if
    generation of slurry is expected to occur.
    QCS 2014 Section 01: General Page 12
    Part 24: Construction Dewatering

    24.4.2 Contamination of Groundwater

    1 In the event of discovering the contamination of the receiving environment such as


    groundwater by dewatering effluent, the contractor is obligated to report the discovery to the
    licensing authority (ASHGHAL, MoE) and the effluent is to be dealt with as per the
    construction Environmental Management Plan (CEMP). Samples of groundwater should be
    taken and tested. Reasonable suspicion can be established by one of the following
    methods:
    (a) Possible history of contamination in the area; such as prior land use (eg. petrol
    station), or the area is known to have septic tank issues.
    (b) EIA: if there is an EIA prepared for the project, it should be reviewed and approved by
    MoE in order to eliminate the possibility of contamination. If the EIA indicates the
    presence of contamination, the Contractor is obligated to report the findings to MoE for

    .
    their feedback, and test for the type of contamination detected in the EIA.

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    (c) The Contractor shall use the following Water Quality Assessment to establish the

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    possibility of contamination in the area.

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    Water Quality Assessment
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    The following questions provide n initial assessment of the quality of the water to be
    discharged from the dewatering operation.
    1. Review the project records. Is there any reason to suspect that the
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    water may be polluted by something other than sediment?


    Common No Yes
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    Sense Test
    2. Is the water located in an area of known contamination?
    No Yes
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    Does the water have an abnormal visual feature, such as: (circle)
    Sight Test Oily Sheen, Floating Foam, Murky Appearance, Unusual
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    Colour Other
    Does the water have an odor? No Yes
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    Smell Test Possible odors include gasoline, petroleum, ammonia, sewage,


    it

    etc.
    et

    If you answered YES to any of the above questions, explain:


    If you answered YES to any of the questions in the assessment or suspect that the
    m

    water contains pollutants other than sediments, contact the Engineer for assistance
    with additional testing and management options.

    Water Quality Assessments


    ** Adapted from Source: The office of Environmental Engineering, California Department of
    Transportation (Caltrans), Field Guide to Construction Site Dewatering, USA, 2001.
    In the event of discovering groundwater contamination, the Contractor is obligated to report the
    discovery to the Engineer and Licensing Authority (MOE / ASHGHAL) and the effluent is to be dealt
    with as per the Construction Environmental Management Plan (CEMP), or as directed by the
    Engineer.

    24.5 DISPOSAL OPTIONS

    1 Qatar construction sites use four (4) common means of disposal, namely:
    (a) Discharge to sea via the Surface and Groundwater Network;
    QCS 2014 Section 01: General Page 13
    Part 24: Construction Dewatering

    (b) Direct Discharge to the sea;


    (c) (A) Discharge to lagoon totally covered by geotextile from all sides;
    (B) Discharge to lagoon not covered, and;
    (d) Discharge by injection to deep groundwater aquifer (Deep well injection).

    2 The following section discusses the options available in Qatar in terms of dewatering effluent
    disposal, and describes the best option depending on the circumstances of the project.

    24.6 DISCHARGE TO SEA

    24.6.1 Discharge to Sea via Surface and Groundwater Network

    1 Disposal of dewatering effluent to the Surface and Groundwater Network is the most

    .
    common practice in Qatar. The Surface and Groundwater Network eventually leads to

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    outfalls that discharge to Sea.

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    2 The disposal to the network directly via pipelines, or via tankers, depends on the availability
    of Surface and Groundwater Network in the project area.

    3 ta
    The Surface and Groundwater Network is an acceptable option for disposal given that
    qa
    Contractor is also reusing the effluent on site whenever possible.

    4 If a Contractor chooses to discharge to the Surface and Groundwater Network, obtaining a


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    license from ASHGHAL is required to allow the discharge of groundwater to the Surface and
    Groundwater Network. A license from the Ministry of Environment is also required through
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    the submission of an Environmental Permit Application.


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    5 Measurements of flow rates must be undertaken in order to monitor the discharge flow and
    ensure that it is within the limits provided to the licensing authority (refer Appendix A for
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    discharge limits).
    o

    6 The Contractor must provide the licensing authority with the maximum expected flow rate (i.e
    it

    the peak flow) and the expected average flow rate, in order to avoid back flooding when
    et

    flows exceed the capacity of the manhole assigned to the Contractor. Therefore, the
    contractor should install a flow meter at the construction site in order to measure the
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    quantities of groundwater flow.

    7 The Contractor should also notify the licensing authority if peak flows are expected to be
    reached frequently during the winter season, particularly when heavy rain is forecast, so as
    to avoid penalties if the manhole back floods.

    8 If a Contractor is operating from an area which is not served by a Surface and Groundwater
    Network, and determines that the most cost effective solution is to use tankers to transport
    dewatering effluent to the nearest assigned manhole, the Contractor is then obligated to
    provide a brief statement demonstrating the traffic impacts caused by their tankers.

    9 If the resultant traffic impact proves to be significant, the Contractor is either to consider
    other options of disposal, or retain dewatering effluent onsite and then transport the effluent
    when traffic is less congested, therefore minimising traffic impacts.
    QCS 2014 Section 01: General Page 14
    Part 24: Construction Dewatering

    10 In the event that tankers are used to transport dewatering effluent, in order to monitor
    discharge to Surface and Groundwater Network the Contractor must record all particulars
    associated with its removal, such as:
    (a) Installing a flow meter at the construction site in order to measure the quantities of
    groundwater flow.
    (b) Record of tankers coming to and leaving the site (eg. registration plate no., capacity,
    records of water quality)
    (c) Volumes of effluent transported.

    11 The recording of tanker movements is in addition to the installation of a meter on the


    weir/sediment tank.

    12 When applying for the discharge permit the following documents are required:

    l .
    (a) Official letter from the company addressed to: The Manager of Drainage Networks

    .l.
    O&M Dept- Asset Affairs- ASHGHAL. (Includes start and end date of dewatering

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    works & method of statement for dewatering).
    (b) Application form for pumping groundwater to be filled and stamped.
    (c) Copy of building permit.
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    (d) Copy of the site map.
    (e) Copy of ID card of the applicants engineer.
    as

    (f) Copy of the registration company.


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    (g) Copy of Road Opening (RO) Permit.


    (h) Copy of Traffic Department Approval, as part of the RO Permit
    er

    (i) Testing of samples, and conformation of compliant results prior to obtaining the two-
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    month permit. The Contractor must note that the sample testing is to be carried out
    after obtaining the five-day temporary permit, and is to be submitted after the previous
    requirements are submitted and a temporary permit is granted.
    it o

    13 Once the application is submitted, the project is given a reference number which includes a
    et

    serial number, type of discharge (e.g groundwater) and the date of application. Drawing and
    m

    comments are then returned to the applicant for information and/or action and the applicant
    will be advised the applicable disposal option and a manhole to be assigned for the
    discharge.

    14 The applicant is issued a temporary permit for five days. The purpose of the temporary
    permit is to allow the applicant to obtain approvals from the concerned authorities, and install
    the equipment in order to take water samples.
    QCS 2014 Section 01: General Page 15
    Part 24: Construction Dewatering

    15 During the temporary dewatering permit; only discharge is allowed for collecting samples
    and to proceed with other department requirements. All samples are taken by laboratory
    representative from the list of laboratories approved by ASHGHAL and MOE; its prohibited
    for samples to be taken by the Contractor. The collected samples should be tested for Total
    Suspended Solids (TSS, turbidity and the short list of parameters included in Appendix A.
    Test results should be uploaded online to QSD by the laboratory. Yet, it should be
    highlighted here that any testing activities are not only limited to the parameters provided on
    the short list developed by QSD; it should also cover the list of parameters required by MOE
    for dewatering permit. Approval is then granted if the test results meet the requirements of
    discharge. The Quality Limits are attached in Appendix A.

    16 If the installation requires a road crossing, a RO permit is required. If not, a RO is not


    required. The applicant must obtain a license from the concerned authorities for installation
    of all tanks and hoses.

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    17 Following the issuance of the permit, regular inspections by the O&M staff are carried out.
    The Contractor is then required to undertake weekly laboratory tests for TSS and turbidity of

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    effluent samples, and bi-monthly tests prior to renewing the permit. Permit renewal request
    should be submitted in 7 days advance before expiry day of the previous permit. The bi-
    monthly tests are for TSS, turbidity and the short list of parameters included in Appendix A
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    together with the parameters listed under Annex (4) of the law of Environment number
    qa
    30/2002.

    18 A copy of the Permitting Application and pro-forms are attached in Appendix C.


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    19 Refer to Appendix D for a flowchart of the permitting procedure for the discharge to sea via
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    Surface and Groundwater network.


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    24.6.2 Direct Discharge to Sea


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    1 MOE is the licensing authority for discharging dewatering effluent direct to the Sea.

    2 If a Contractor found that the applicable option for dewatering is the direct discharge to sea,
    o

    a secondary method of treatment must be installed to allow the dewatering effluent to settle
    it

    before reaching the discharge outfall point. The discharge to the outfall point is achieved
    et

    through the use of pipelines or transportation via tankers. Based on the number of tankers,
    m

    the transportation may be subjected to a traffic impact assessment study based on the
    requirements of MOE.

    3 The Contractor may therefore be subject to a number of pertinent laws and regulations:

    4 When issuing direct sea discharge permits, MOE have the following concerns that need to
    be addressed as per Annex 4 of the Qatari Law of Environment and the list of parameters
    required by MOE for dewatering permit (included in Appendix A), which includes the test of
    the following parameters:
    (a) Bacterial counts
    (b) Turbidity and TSS levels
    (c) Presence of Petroleum compounds.
    (d) Presence of heavy metals.
    (e) Others, as per MoE requirements.
    QCS 2014 Section 01: General Page 16
    Part 24: Construction Dewatering

    5 Refer to Appendix D for a flowchart of the permitting procedure for the direct discharge to
    sea. A copy of the environmental permit application form is included in Appendix E.

    6 For more information, contact MoE on:


    Telephone +974 4420 7777
    Fax + 974 4420 7000
    Email Responsibility@moe.gov.qa

    24.6.3 Discharge to Lagoons:

    A. Discharge to Lagoon totally covered with geotextile from all sides

    1 Lagoons are licensed by MOE.

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    2 It is recommended that a lagoon totally covered with geotextile from all sides, formed in a
    depressive area, is used in locations where it is logistically impossible or cost and socially

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    prohibitive to deliver effluent to the Surface and Groundwater Network using other means.

    3 If Contractor chooses to discharge the dewatering effluent to a lagoon, license is given by


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    MOE. The dewatering to lagoons is mainly based on the requirements by MOE which is
    qa
    given for case by case. The use of this option is depending on the water quality. Yet, the
    general requirements of MOE can be summarised in the following information:
    as

    (a) Dewatering effluent quantity.


    (b) Detailed Engineering drawings for the lagoon showing the geotextile lining of the
    se

    lagoon.
    er

    (c) Duration of dewatering discharge


    (d) Dewatering effluent quality. Dewatering effluent quality is tested initially against the list
    ov

    of parameters required by MoE for dewatering permit (included in Appendix A). And
    then tested weekly. Monthly testing is also required for selected parameters.
    o

    (e) Coordinates of lagoon, inclusive of dewatering discharge points.


    it
    et

    (f) Location map


    (g) Others, as per MOE requirements.
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    4 Refer to Appendix D for a flowchart of the permitting procedure for the discharge through
    the use of lagoons. A copy of the environmental permit application form is included in
    Appendix E.

    5 For more information, contact MOE on:


    Telephone +974 4420 7777
    Fax + 974 4420 7000
    Email Responsibility@moe.gov.qa
    QCS 2014 Section 01: General Page 17
    Part 24: Construction Dewatering

    B. Discharge to Lagoon not covered

    6 The discharge to a logon which is not covered is depending on the discharged water quality.
    Similar to the above option, the licensing authority for this option is the Ministry of
    Environment. The list of parameters required by MOE for dewatering permit is included in
    Appendix A. The general requirements of MOE are similar to the above option.

    7 Refer to Appendix C for a flowchart of the permitting procedure for the discharge through
    the use of lagoons. A copy of the environmental permit application form is included in
    Appendix E.

    8 For more information, contact MOE on:


    Telephone +974 4420 7777
    Fax + 974 4420 7000

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    Email Responsibility@moe.gov.qa

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    24.6.4 Discharge by injection to deep groundwater aquifer (Deep well injection)

    1
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    Disposal by injection to groundwater aquifer is a common method in Qatar to dispose of
    treated effluent of sewage treatment plants. Yet, the use of deep well injection for the
    qa
    discharge of dewatering effluent to groundwater aquifer is also done in few big projects.

    2 However and prior to the discharge to the deep well, a careful assessment of geological
    as

    conditions must be conducted in order to determine the suitable depth and location of porous
    aquifer reservoirs and identifying the safe rate of injection to the deep aquifer. Generally, the
    se

    depth of the deep well should not be less than 400 600 m deep, which is the expected
    depth of Umm Er Radhumma (UER) aquifer.
    er

    3 In all cases, MOE require the contractor to conduct an Environmental Assessment for the
    ov

    impact from the project as soon as drilling of the deep well and the analysis of the samples is
    achieved. This shall be done by a qualified consultant with previous experience in similar
    o

    projects.
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    et

    4 The general requirements of MOE for the use of the deep well injection can be summarised
    in the following information:
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    (a) Duration of dewatering discharge.


    (b) Dewatering effluent quality. Dewatering effluent quality is tested initially against the
    parameters specified in the standards for the water use for irrigation purpose of the
    Qatari Law of Environment. And then periodically testing each week based on MoE
    requirements.
    (c) The parameters required for the physical, chemical, biological, microbiological
    analysis includes but not limited to: EC, Temperature, DO, pH, Turbidity, FRC, TPH,
    O&G, Sulphide, Metals, BOD, COD, TOC, surfactants, VOC, BETX, TDS, TSS, PAHs,
    TAlk, Nitrate, Nitrite, Ammonia, TKN, Phosphorus, Chloride, Sodium, Sulphite, Total
    Phenol, Carbonate, E-Coli, Faecal Coliform, Bacteria and SAR.
    (d) A0 design map for the whole project including the location of the injection well and
    network of shallow trenches connecting the wells.
    (e) Comparison study between the use of the shallow networking and the perforated
    pipelines.
    QCS 2014 Section 01: General Page 18
    Part 24: Construction Dewatering

    (f) Drilling of monitoring wells to suitable depth to monitor the impact on the shallow
    aquifer.
    (g) Providing the injection wells with emergency valves to stop injection in case of
    contamination.

    5 Refer to Appendix D for a flowchart of the permitting procedure for the discharge through
    the use of deep well injection. A copy of the environmental permit application form is
    included in Appendix E.

    6 As mentioned above, the injection of dewatering effluent to groundwater aquifer is licensed


    by MOE and is completely subject to their approval, therefore for further information, please
    contact MOE on:
    Telephone +974 4420 7777

    .
    Fax + 974 4420 7000

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    Email Responsibility@moe.gov.qa

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    24.6.5 Groundwater Recycle & Reuse Onsite

    1
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    It is recommended, where environmentally safe and cost effective, that dewatering effluent is
    qa
    reused or recycled onsite.

    2 The reuse options onsite will depend on a number of factors, including the type of project.
    as

    The contractor should propose the treatment in case the water is polluted by organic and
    inorganic chemicals or subjected to biological contamination. The treatment should focus but
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    not limited to low DO, presence of Bacteria, elevated levels of TSS or turbidity and presence
    of oil.
    er

    3 The CEMP should be used to identify all opportunities of reuse onsite. Yet, the options for
    ov

    the reuse of the groundwater should be discussed with MOE and shall be subjected to the
    approval by MOE.
    o

    4 Options could include but not be limited to:


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    (a) Control of dust onsite. (Subject to the level of safety and quality of dewatering
    effluent).
    m

    (b) Reuse of dewatering effluent.


    (c) Concrete curing.
    (d) Excavation activities requiring water.
    (e) Washing of machinery and site equipment.
    (f) Watering of onsite landscaping, when the turbidity is very low to avoid compromising
    the integrity of the soil.
    (g) If the dewatering effluent quality is within limits of soil compaction parameters
    requirements (refer to QCS), it can be used for soil compaction purposes.

    5 Contractor to conduct a feasibility study to evaluate whether its feasible to erect an RO


    system for dewatering effluent treatment, in order to use the dewatering effluent instead of
    fresh potable water.
    QCS 2014 Section 01: General Page 19
    Part 24: Construction Dewatering

    6 The feasibility study is to compare both options in terms of financial viability.

    24.6.6 Integrated Management of Construction Dewatering

    1 Construction dewatering practices are better managed if they are integrated with existing
    construction management systems, such as a CEMP, monitoring plan and training
    programmes. The dewatering practice will then form part of the regular construction
    inspection/monitoring program.

    24.6.7 Construction Environmental Management Plan (CEMP)

    1 The CEMP is prepared to minimise the impacts of the project and its activities on the
    receiving environment. The CEMP is prepared prior to mobilising to site.

    2 The Contractor should uses the geotechnical investigations and previous EIA (if applicable)

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    as guidelines when preparing the CEMP.

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    3 When dewatering activities are included within the project site, the preparation of the CEMP
    should include the following:
    (a)
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    Identification of opportunities to reuse the dewatering effluent onsite in order to reduce
    the amount of disposed effluent.
    qa
    (b) Dewatering techniques being employed on site
    (c) Disposal methods employed on-site and relevant monitoring plan to ensure
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    compliance with discharge limits.


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    (d) Copy of discharge limits.


    (e) Roles and responsibilities of the Environmental Advisor on site.
    er

    4 Roles and responsibilities have to be clearly defined when designing a dewatering system.
    ov

    These roles and responsibilities are to be submitted as an essential element to satisfy the
    CEMP requirements when applying for the dewatering effluent discharge permit.
    it o

    5 Refer to Appendix B for an example of inspection sheet for the dewatering process.
    et

    24.6.8 Monitoring Plan


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    1 The environmental monitoring plan is used to monitor the anticipated impacts of the project o
    the surrounding and receiving environments. It is imperative that, should dewatering
    activities exist on site, there is integration all testing and monitoring requirements.

    2 Integration of monitoring plans may be between systems within individual sites or between
    several sites, depending on management systems or owners
    (a) Environmental monitoring plan: The environmental monitoring plan is to outline the
    steps required for monitoring of construction dewatering practices. The integration of
    dewatering practices into the monitoring plan will pave the way to introduce a
    dewatering monitoring plan.
    (b) The findings of the dewatering monitoring reports are to be summarised and included
    in the environmental monitoring reports.
    QCS 2014 Section 01: General Page 20
    Part 24: Construction Dewatering

    (c) The dewatering practices monitoring plan: Introduction of a dewatering practices


    monitoring plan, sampling points, variables, frequencies and reporting. This plan
    should be cyclic which stands to be audited as part of the master environmental
    monitoring plan. Corrective actions from audits are to be implemented to ensure
    improved performance.

    24.6.9 Training Plan

    1 The integration of construction dewatering training into the training plan of the Contractor is
    essential to introduce all staff to construction dewatering related information.

    2 It is recommended that information on dewatering equipment and related emergencies are


    included in the training provided to staff entering or working on the site.

    3 The training for all staff does not have to be comprehensive; however, it should include basic

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    items such as:

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    (a) Brief explanation of the construction dewatering purpose

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    (b) Introduction to the dewatering equipment. Inclusion of photos in the training
    presentation.
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    Health and safety related concerns, education on related emergencies, and contact
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    information of person in charge of dewatering to be provided in the presentation.

    4 Training for dewatering staff, however, should be the responsibility of the Project Consultant
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    and as per each Project needs and requirements. The training should be comprehensive and
    should include all components dewatering staff need to be familiar with.
    se

    24.6.10 Odour Control


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    1 The odour levels have been given a threshold value as indicated in the Qatar Construction
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    Specifications (QCS). Therefore, it is highly recommended to measure the level of odour


    parameters, a devise should be installed within the construction site to measure odour
    o

    parameters (eg: H2S).


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    2 The QCS has identified two types of odour control equipment; control equipment carbon type
    and control equipment scrubber type. Refer to Section 9 Part 9 and Part 10 for details.
    m

    24.6.11 Health & Safety Considerations

    1 Health and safety issues are the most important part of any construction project. It is
    recommended that health and safety measures in relation to dewatering practices are
    enforced strictly, in order to prevent and/or minimise on-site accidents.

    2 In addition to the conventional health and safety measures implemented in construction


    sites, the following considerations are to be incorporated to contribute to the health and
    safety practices relating to construction dewatering:
    QCS 2014 Section 01: General Page 21
    Part 24: Construction Dewatering

    24.6.12 Site Investigation

    1 During the initial site investigations, the Contractor has to identify potential health and safety
    risks in the project area. Examples of risks are: potential contamination posing health and
    safety concern to labour workers and site staff, slope stability issues due to dewatering
    practices... etc.

    2 Identified risks have to be considered and mitigated against during design and execution of
    dewatering.

    3 This exercise can be undertaken during the Risk Assessment process as described earlier in
    this Guideline.

    24.6.13 Design Considerations

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    1 The design of dewatering stage is the most convenient stage to plan properly in order to

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    prevent foreseeable health and safety issues arising during operational dewatering.

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    2 All designs must take into account the health & safety considerations associated with
    dewatering, which include but are not limited to:
    (a) ta
    Preparation of layout plan for dewatering equipment.
    qa
    (b) Ensure access to dewatering equipment, without compromising the safety of staff.
    (c) Ensure that all dewatering equipment especially equipment placed offsite- is marked
    as

    clearly with name of project and Contractor, and contact person details.
    se

    (d) Provide protective covers for assigned manholes which do not hinder the discharged
    flow.
    er

    (e) The mandatory use of PPE. All staff entering a projects safe zone have to be wearing
    appropriate safety gear. This also applies to staff managing dewatering equipment
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    offsite.
    (f) The Contractor is to exercise duty of care when designing, installing and operating the
    o

    dewatering equipment and process.


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    et

    24.6.14 Housekeeping Considerations


    m

    1 It is recommended that during the regular inspection of projects, the licensing authority is to
    observe the status of housekeeping of dewatering equipment. Inadequate housekeeping can
    expose staff and visitors to injury.
    QCS 2014 Section 01: General Page 22
    Part 24: Construction Dewatering

    APPENDICES

    Appendix A: Short List of Parameters as provided by ASHGHAL- 23


    MoE list of Parameters for Dewatering Permit -
    Environmental Laws and Regulations- Annex 4, Law 30 of 2002

    Appendix B: Dewatering Process Inspection Sheet 32

    Appendix C: Discharge Permit Forms 36

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    Appendix D: Application for Permit- Procedure Flowchart for each Dewatering Option 40

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    Appendix E: Environmental Permit Application- MoE 45

    Appendix A ta 23
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    SHORT LIST OF PARAMETERS AS PROVIDED BY ASHGHAL 23
    MOE LIST OF PARAMETERS REQUIRED FOR DEWATERING PERMITS 23
    ENVIRONMENTAL LAWS AND REGULATIONS ANNEX 4, LAW 30 OF 2002 23
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    Appendix B 32
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    DEWATERING PROCESS INSPECTION SHEET 32


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    Appendix C 36
    DISCHARGE PERMIT FORMS 36
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    Appendix D 40
    APPLICATION FOR PERMIT PROCEDURE FLOWCHART FOR
    o

    EACH DEWATERING OPTION 40


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    Appendix E 45
    ENVIRONMENTAL PERMIT APPLICATION MOE 45
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    QCS 2014 Section 01: General Page 23
    Part 24: Construction Dewatering

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    Appendix A
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    Short List of Parameters as provided by Ashghal


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    MoE list of Parameters required for Dewatering Permits


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    Environmental Laws and Regulations Annex 4, Law 30 of 2002


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    QCS 2014 Section 01: General Page 24

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    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 25
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 26
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    QCS 2014 Section 01: General Page 27
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    QCS 2014 Section 01: General Page 28
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 29
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    QCS 2014 Section 01: General Page 30
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 31
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 32
    Part 24: Construction Dewatering

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    Appendix B ta
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    Dewatering Process Inspection Sheet
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    QCS 2014 Section 01: General Page 33
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 34
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 35
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 36
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    Appendix C
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    Discharge Permit Forms
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    QCS 2014 Section 01: General Page 37
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 38
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    QCS 2014 Section 01: General Page 39
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    QCS 2014 Section 01: General Page 40
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    Appendix D
    Application for Permit Procedure Flowchart for each Dewatering Option

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    QCS 2014 Section 01: General Page 41
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 42
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    QCS 2014 Section 01: General Page 43
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    QCS 2014 Section 01: General Page 44
    Part 24: Construction Dewatering

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    QCS 2014 Section 01: General Page 45
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    Appendix E
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    Environmental Permit Application MoE
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    QCS 2014 Section 01: General Page 46
    Part 24: Construction Dewatering

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 7
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 8
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 9
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 10
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 11
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 12
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 13
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 14
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 15
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 16
    Part 15: Appendix B - Templates

    15.2 CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 17
    Part 15: Appendix B - Templates

    15.3 QUALITY NON-CONFORMANCE TEMPLATE

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    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 02: Submittals

    2 SUBMITTALS .......................................................................................................... 2
    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Project Quality Plan 2
    2.1.2 Quality Organisation Plan 3
    2.1.3 Inspection and Test Plans 4
    2.1.4 Quality Checklists 5
    2.1.5 Key Performance Indicators 5
    2.1.6 Method Statements 6
    2.1.7 Commissioning Plan 6

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 02: Submittals

    2 SUBMITTALS

    2.1 GENERAL

    2.1.1 Project Quality Plan

    1 The Contractor shall prepare the necessary Contract specific Project Quality Plan as
    specified in this Section, the Contract Documents and as a minimum meeting the
    requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and
    approval within 30 days of the award of Contract. The Contractor is not permitted to Work on
    the worksite until such time as the plan has been approved by the Engineer.

    2 The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor
    shall undertake a full formal review of the quality plans annually with reference to the date of

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    award of the Contract and submit the findings of the review to the Engineer within 14 days of

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    that date along with an amended plan should any amendments be required.

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    3 The Project Quality Plan shall describe the Contractors Quality Management System that will
    be used throughout the Contract and the contents shall include but not be limited to the
    following:
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    (a) Front Cover
    (b) Table of Contents
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    (c) Project Scope, Requirements and Quality Objectives


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    (d) Quality Policy and ISO 9001 Certificate (if applicable)


    (e) Control of Project Quality Plan
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    (f) Reference Documentation


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    (g) Project Management, Planning and Resources


    (h) Management, Organisation and Responsibilities
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    (i) Contract Review


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    (j) Project Deliverables


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    (k) Communication with the Engineer


    (l) Management of Documents, Data and Records
    (m) Design (Including Temporary Works)
    (n) Procurement of Services, Equipment and Materials
    (o) Method Statements
    (p) Inspection and Test
    (q) Product Identification and Traceability
    (r) Owner Supplied Product
    (s) Handling, Storage, Packaging and Delivery
    (t) Non-conformance, Corrective and Preventative Action
    (u) Control of Inspection, Measuring and Test Equipment
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 02: Submittals

    (v) Audits
    (w) Training
    (x) Key Performance Indicators and Continual Improvement
    (y) Management Review
    (z) Quality Meetings
    (aa) Monthly Quality Report
    (bb) Commissioning
    (cc) Interface Management
    (dd) Project Completion and Handover
    (ee) Appendices

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    4 And include as a minimum:

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    (a) a detailed description of procedures, instructions, and reports to be used to ensure
    compliance with the Project Documentation
    (b) a detailed description of procedures for reviewing shop drawings, samples, certificates
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    and other submittals necessary for compliance with the Project Documentation
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    (c) a detailed description of procedures used to identify, report and resolve problems
    (d) a description of the services provided by outside organisations such as testing
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    laboratories, architects, and consulting engineers


    (e) a detailed description of inspections and tests required
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    (f) copies of forms and reports to be used to document quality assurance operations
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    (g) the names of personnel responsible for each part of the Works
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    (h) a submittal status log listing required submittals and action required by the Contractor
    and Engineer
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    (i) a detailed description of document and submittal control procedures


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    (j) an inspection and test schedule keyed to the construction programme


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    (k) procedures to identify and control the use of items and materials
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    5 No construction shall begin and no requests for payment from the Contractor shall be
    processed until the Contractors Project Quality Plan is approved.

    6 A Contractors Project Quality Plan Template with guidance notes is included in Part 15
    Appendix B of this Section. The format of the Contractors Project Quality Plan must follow
    this template including all clauses contained within.

    2.1.2 Quality Organisation Plan

    1 The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later
    than thirty (30) days from the start of the Contract.

    2 The Quality Organisation Plan shall provide the names, qualifications, experience and skills
    of all the QA/QC Team including Corporate QA/QC Manager, Quality Management
    Representative and key support staff.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 02: Submittals

    3 The Quality Organisation Plan shall show the organisation of Contractors quality team and
    shall include, but not be limited to, the following:

    (a) an organisation chart identifying all personnel responsible for quality


    (b) Identify the quality team showing that the team is independent of the job supervisory
    staff with clear lines of authority to top tier management.
    (c) Indicate and describe the area of responsibility and authority of each individual in the
    quality assurance team.

    4 The Quality Organisation Plan should also define quality responsibilities of any of the
    Contractors team with responsibilities under the Contractors Project Quality Plan.

    5 The Contractors Quality staff shall have relevant educational and professional qualifications,
    and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of

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    the works at the worksite until such time as approved quality personnel have been deployed

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    on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed
    quality personnel without prior approval from the Engineer.

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    6 The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a

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    standalone document and cross-referenced within the Project Quality Plan.
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    2.1.3 Inspection and Test Plans

    1 As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan
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    Schedule to the Engineer for approval no later than thirty (30) days from the start of the
    Contract.
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    2 The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be
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    prepared for the Works and the target dates for their submission to the Engineer for his
    approval.
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    3 The Inspection and Test Plans shall consider the requirements of each Section of the
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    Specification and shall identify, as a minimum, the following:


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    (a) Details each activity, inspection and test to be performed


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    (b) Reference to specifications, standards etc.


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    (c) the required inspection and testing frequency


    (d) the acceptance/rejection criteria
    (e) whom from the Contractors team is responsible and qualified to perform the inspection
    or test
    (f) Quality Records to be generated
    (g) Hold, Witness, surveillance and Record Review points of the Contractors team, the
    Engineer and any other agencies having jurisdictional authority over the work relating
    to each inspection and test to be performed.

    4 Each inspection and test shall have a unique reference number.

    5 Inspection and Test Plans are required to address the Contractors on and off site Work and
    preparation, submission and approval of related documentation.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 02: Submittals

    6 Inspection and Test Plans are required for all operations including major temporary works
    and commissioning.

    7 No work covered by the Inspection and Test Plan shall begin until the plan has been
    approved by the Engineer.

    8 A Contractors Inspection and Test Plan Template with guidance notes is included in
    Appendix B of this Section and must be used by the Contractor

    2.1.4 Quality Checklists

    1 The Contractor shall develop specific quality checklists for all activities to be checked as per
    the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection
    Test Plans submission prior to the start of the activity.

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    2 The Contractor shall inspect the work and sign off the relevant checklist and Inspection

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    Request prior to the final inspection with the Engineer.

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    3 The checklist shall be attached with the Inspection Request and other relevant attachments
    and submitted to the Engineer.

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    1 The Contractor shall develop and report Key Performance Indicators (KPIs). KPIs are a set
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    of quantifiable measures that are used to gauge performance of the Contractors


    Performance.
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    2 The KPIs shall be defined in the Contractors Project Quality Plan and be subject to
    Engineers approval.
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    The Contractor is responsible for developing his own KPIs for all elements of his contract
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    (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPIs.
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    (a) Time between identification of a Nonconformance or Corrective Action and actual


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    raising on the system.


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    (b) Time between opening and closure of Nonconformance Reports (NCR) and Corrective
    Action Requests (CAR).
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    (c) NCR and CAR statistics per areas, sections, discipline, subcontractor etc.
    (d) Percentage of reoccurring NCRs and CARs Trends on NCRs and CARs.
    (e) Approval status of critical documentation for the progress of the works (Method
    Statements, ITPs etc.).
    (f) Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed,
    pass first time, etc.).
    (g) Completion packages (As-Built folders) progress.

    4 Reporting of the KPIs shall include a graphical bar chart representation on a month by month
    basis from the start of the Contract.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 6
    Part 02: Submittals

    2.1.6 Method Statements

    1 Contractor shall ensure that Method Statements address quality issues. Refer to Section 11
    Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in
    particular section 2.4

    2.1.7 Commissioning Plan

    1 The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than
    sixty (60) days unless agreed otherwise with the engineer before the start of the
    commissioning of the Works or any part thereof.

    2 The Commissioning Plan shall consider the requirements of each Section of the Specification
    in turn and shall identify the following:

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    (a) all required commissioning work required by that Section of the Specification

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    (b) any prerequisites to commissioning

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    (c) a list of the commissioning procedure
    (d) a detailed description of the duties and responsibilities on the personnel involved in the
    commissioning process
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    (e) a detailed list of the tests/checks/activities that will be performed, linked to the relevant
    construction activities and referenced to any links/documents to the ITPs performed
    during the construction
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    (f) specific reference to the witness/hold and review points of the engineer
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    (g) a detailed list of the standards /specifications/regulatory requirements that need to be


    performed
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    (h) a detailed description of the interactions/communication between different


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    organization/public service or other legal/regulatory institutions


    (i) a detailed description of the test/activities of the maintenance needed during the life
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    time of the project, with reference to any special requirements/qualifications of the


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    personnel involved in the maintenance activities


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    (j) a detailed description of any spare parts/equipment/fixtures and other type of the of
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    consumables that might be needed, with an estimation of quantities, for the life time of
    the project
    (k) a detailed description of the as built project file that will be created after the
    commission phase
    (l) a procedure for up-date and revision of the commissioning plan

    3 No work covered by the Commissioning Plan shall begin until the plan has been approved.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 03: Contractors Quality Personnel

    3 CONTRACTORS QUALITY PERSONNEL ............................................................. 2


    3.1 INTRODUCTION ..................................................................................................... 2
    3.1.1 General 2
    3.1.2 Quality Assurance Manager 2
    3.1.3 Quality Control Manager 2
    3.1.4 Quality Engineer 2
    3.1.5 Quality Inspector 3
    3.1.6 Personnel Qualifications 3
    3.1.7 Quality Staff Requirement 3
    3.1.8 Quality Training for Contractors Employees and Labour 5

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 03: Contractors Quality Personnel

    3 CONTRACTORS QUALITY PERSONNEL

    3.1 INTRODUCTION

    3.1.1 General

    1 Contractor shall, throughout the execution and completion of the Works and the remedying
    defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only
    with matters regarding the quality and protection against damage before, during and after
    execution of Works as specified in this section. This team shall be qualified and experienced
    in their work and shall have the authority to issue instructions and shall take protective
    measures to prevent execution of Works that do not comply with the Specifications.

    2 The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any

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    of the quality team designated in the Quality Organisation Plan.

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    3 The Contractor shall have adequate quality personnel on the site during all production
    operations, including adequate coverage during night shift operations and off site work.

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    The Contractor's quality team shall have the authority to stop any portion of the work which
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    does not comply with the requirements of the Project Documentation.

    5 Minimum qualifications and experience of the Contractors Quality Personnel shall be as


    as

    defined in the Contract.


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    3.1.2 Quality Assurance Manager


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    1 Where required by this section, the Contractor shall designate and assign a full time Quality
    Assurance Manager who shall be responsible for overseeing the implementation and
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    operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report
    directly to Top Tier Management and be independent of the Contractors organisation
    responsible for construction.
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    3.1.3 Quality Control Manager


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    1 Where required by this section, the Contractor shall designate and assign a full time Quality
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    Control Manager who reports directly to the Quality Assurance Manager and shall be
    responsible for supervision of the construction quality control management activities and
    ensuring compliance with the Contractors Inspection and Test Plans and associated
    specification and contract documentation.

    3.1.4 Quality Engineer

    1 Where required by this section, the Contractor shall designate and assign a Quality Engineer
    who reports directly to the Quality Assurance Manager or Quality Control Manager and shall
    be responsible for assisting them with their day to day responsibilities and may be
    assigned to cover several locations or areas of work relating to the Contract. Where a Quality
    Assurance Manager or Quality Control Manager are not required by this section the Quality
    Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 03: Contractors Quality Personnel

    3.1.5 Quality Inspector

    1 The Contractor shall designate and assign a Quality Inspector for each shift for each location
    where work is being performed. Each Quality Inspector shall be qualified by training and
    experience in all the construction or fabrication activities being conducted at the location of
    work and is directly responsible for ensuring compliance with the Contractors Inspection and
    Test Plans and associated specification and contract documentation.

    3.1.6 Personnel Qualifications

    1 The Contractor shall identify activities requiring qualified production, inspection, and test
    personnel and establish their minimum competence level.

    2 The Contractor shall maintain records of personnel qualifications as quality records.

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    3.1.7 Quality Staff Requirement

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    1 Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified
    quality personnel for the Work as per below tables.

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    Quality Staff Requirement
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    No No of workers on Worksite Requirement
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    1 Quality Inspector (Part time, 15 hours of duty per


    1. Less than 10
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    week)
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    2. More than 11 but less than 50 1 Quality Inspector


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    1 Quality Engineer and


    3. More than 51 but less than 500
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    1 Quality Inspector per 100 workers


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    1 Quality Assurance Manager and


    4. More than 501 but less than 1500 1 Quality Engineer per 500 workers and
    1 Quality Inspector per 100 workers

    1 Quality Assurance Manager and


    1 Quality Control Manager and
    5. More than 1501
    1 Quality Engineer per 500 workers and
    1 Quality Inspector per 100 workers
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 03: Contractors Quality Personnel

    Quality Management and Control staff Qualifications & Experience Matrix

    Minimum Qualifications Minimum Years of Minimum Key


    Position
    Required Experience Competencies

    Quality Degree in relevant 12 years, 5 of which at Qualified Professional who


    Assurance Engineering discipline and Management Level and 3 can manage a Quality
    Manager related training in Quality years Regional experience Management System and
    Management Techniques. coordinate specialised
    Internationally recognised activities. Excellent written
    Lead Auditor Certificate & verbal communication
    skills in English

    Quality Control Degree in relevant 12 years, 5 of which at Excellent written & verbal

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    Manager Engineering discipline and Management Level and 3 communication skills in

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    related training in Quality years Regional experience English
    Management Techniques.

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    Internationally recognised
    Lead Auditor Certificate
    Quality Engineer Degree in relevant
    Engineering discipline. ta
    10 years experience in
    related Quality Control
    Good written & verbal
    communication skills in
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    Internationally recognised Activities and 3 years English
    Lead Auditor Certificate Regional experience
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    Quality Inspector Certificate or Diploma in 5 years experience in Good written & verbal
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    the appropriate related Quality Control and communication skills in


    engineering discipline Materials Testing activities English
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    along with 2 years


    Regional Experience
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    2 The Contractor shall appoint deputy quality personnel who are capable of performing all the
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    duties of the quality personnel in the event of their absence.


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    3 The Contractor shall appoint support staff in sufficient numbers to ensure the effective
    function of the quality related work within the Contractors organisation.

    4 The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints
    suitably qualified quality staff to ensure the effective function of the quality related issues
    within the Sub-contractors organisation. The Sub-contractor shall appoint and deploy fulltime
    on the Worksite one Quality Inspector for every 100 workers that they employ at the
    Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality
    Engineer. This shall be in addition to the Contractors Quality Team.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 03: Contractors Quality Personnel

    3.1.8 Quality Training for Contractors Employees and Labour

    1 The Contractor shall conduct quality training including Contract specific induction, pre-work
    briefings, skills training, tool box talks and formal training conducted by training professionals
    or agencies for all the Contractors employees. The Contract specific induction will be at least
    1 hour duration, approved by the Engineer and provided for all persons involved in the
    Works. Such induction training will be reviewed, revised and repeated at intervals not
    exceeding 12 months throughout the duration of the Work. All training shall be provided in the
    languages preferred by the recipients of the training. Training shall focus on improving
    competency and skill for those performing activities that impact quality.

    2 The Contractor must conduct regular tool box talks to his Labour workforce Such training
    should include as a minimum Health and Safety issues and Construction Method best
    practice.

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    3 The Owner may organise quality related training, meetings, seminars, workshops or similar

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    events at any time throughout the Contract Period. The Contractor is required to participate

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    in such events when requested at his own expense.

    4 The Contractor shall maintain records of all training conducted including details of the training

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    given and a list of attendees, including attendees signature and ID numbers.
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    END OF PART
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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 04: Document & Data Control

    4 DOCUMENT & DATA CONTROL ............................................................................ 2


    4.1 INTRODUCTION ..................................................................................................... 2
    4.1.1 General 2
    4.1.2 Document and Data Approval and Issue 2
    4.1.3 Document and Data Changes 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 04: Document & Data Control

    4 DOCUMENT & DATA CONTROL

    4.1 INTRODUCTION

    4.1.1 General

    1 The Contractor shall establish and maintain documented procedures to control all documents
    and data that relate to the requirements of the Specification. Documents and data can be in
    the form of any type of media, such as hard copy or electronic media.

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

    4.1.2 Document and Data Approval and Issue

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    1 The documents and data shall be reviewed and approved for adequacy by authorised

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    personnel prior to issue. A master list or equivalent document control procedure identifying
    the current revision status of documents shall be established and be readily available to
    preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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    The pertinent issues of appropriate documents are available at all locations where
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    operations essential to the effective functioning of the quality system are performed
    (b) Invalid and/or obsolete documents are promptly removed from all points of issue or
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    use, or otherwise assured against unintended use


    (c) Any obsolete documents retained for legal and/or knowledge preservation purposes
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    are suitably identified


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    4.1.3 Document and Data Changes


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    1 Where practicable, the nature of the change shall be identified in the document or
    appropriate attachments.
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    END OF PART
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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 05: Quality Records

    5 QUALITY RECORDS..................................................................................... 2
    5.1 INTRODUCTION ........................................................................................... 2
    5.1.1 General 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 05: Quality Records

    5 QUALITY RECORDS

    5.1 INTRODUCTION

    5.1.1 General

    1 The Contractor shall establish and maintain documented procedures for identification,
    collection, indexing, access, filing, storage, maintenance and disposition of quality records.

    2 The Contractor shall supplement these quality records as necessary to monitor quality
    throughout the Contract period.

    3 Quality records shall be maintained to demonstrate conformance of materials and equipment


    to specified technical requirements and the effective operation of the quality system.

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    4 All quality records shall be legible and shall be stored and retained in such a way that they

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    are readily retrievable in facilities that provide a suitable environment to prevent damage or
    deterioration and to prevent loss.

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    As a minimum, the quality record for any particular item shall include:
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    (a) name of item
    (b) item number
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    (c) item description


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    (d) suppliers name


    (e) serial number or other identification (where applicable)
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    (f) Specification reference (where applicable)


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    (g) verification of receipt of all required supporting documentation


    (h) quantity of items
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    (i) location and installation of item


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    (j) inspection/test procedure reference


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    (k) non-conformance number (if applicable)


    (l) Observations / comments.
    (m) Signatures of responsible person

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 06: Quality Audits

    6 QUALITY AUDITS ................................................................................................... 2


    6.1 GENERAL ............................................................................................................... 2
    6.1.1 Contractors Quality Audit 2
    6.1.2 Engineers Quality Audit 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 06: Quality Audits

    6 QUALITY AUDITS

    6.1 GENERAL

    6.1.1 Contractors Quality Audit

    1 The Contractor shall establish and maintain documented procedures in line with ISO 190011
    for planning and implementing internal quality audits to verify whether quality activities and
    related results comply with planned arrangements and to determine the effectiveness of the
    quality system.

    2 Internal quality audits shall be scheduled on the basis of the status and importance of the
    activity to be audited and shall be carried out by personnel independent of those having direct
    responsibility for the activity being audited. Unless otherwise agreed with the Engineer in

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    writing, the Contractor shall carry out a full system quality audit every three months.

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    3 The results of the audits shall be recorded and brought to the attention of the personnel
    having responsibility in the area audited. The management personnel responsible for the
    area shall take timely corrective action on deficiencies found during the audit.

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    4 Follow-up audit activities shall verify and record the implementation and effectiveness the
    corrective action taken.
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    5 The results of the Contractors quality audits shall be made available for review by the
    Engineer. The Contractor shall implement any recommendations made by the Engineer
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    based on the results of the internal audit.

    The Contractor shall allow the Engineer to observe the Contractors internal audit upon
    er

    6
    request.
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    7 Quality audits must be undertaken by suitably qualified personnel with an internationally


    recognized audit qualification to recognized standards.
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    6.1.2 Engineers Quality Audit


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    1 The Engineer may undertake a quality audit of any of the Contractors activities at any time
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    during the course of the Contract. The Contractor shall make all personnel and facilities
    available to the Engineer as necessary to undertake quality audits.

    2 The Engineer shall make the results of his quality audit available to the Contractor for review.
    The Contractor shall implement any recommendations made by the Engineer based on the
    results of the Engineers quality audit.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 07: Inspection and Test

    7 INSPECTION AND TEST ........................................................................................ 2


    7.1 INTRODUCTION ..................................................................................................... 2
    7.1.1 General 2
    7.1.2 Inspections and Tests 2
    7.1.3 Inspection and Test Status 3
    7.1.4 Inspections by the Engineer during construction 3
    7.1.5 Inspections by the Engineer during Defects Liability Period 4
    7.1.6 Workmanship 4
    7.1.7 Measuring and Test Equipment 4

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 07: Inspection and Test

    7 INSPECTION AND TEST

    7.1 INTRODUCTION

    7.1.1 General

    1 The Contractor shall provide equipment, instruments, qualified personnel, and facilities
    necessary to inspect the work and perform the tests required by the Project Documentation.

    2 The Contractor shall repeat tests and inspections after correcting non-conforming work until
    all work complies with the requirements. All re-testing and re-inspections shall be performed
    at no additional cost to the Client.

    3 The Engineer may elect to perform additional inspections and tests at the place of the

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    manufacture or the shipping point to verify compliance with applicable Specifications.

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    Inspections and tests performed by the Engineer shall not relieve the Contractor of his

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    responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be
    considered a guarantee that materials delivered at a later time will be acceptable. All costs
    associated with the foregoing shall be borne by the Contractor.

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    Inspections and tests conducted by persons or agencies other than the Contractor, shall not
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    in any way relieve the Contractor of his responsibility and obligation to meet all Specifications
    and referenced standards.
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    7.1.2 Inspections and Tests


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    1 All inspections and tests shall be conducted in accordance with written test procedures as
    detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed
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    and approved by the Engineer.


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    2 Mandatory Products and Materials Sampling and Testing Frequencies are included in Part
    14, Appendix A of this section. The Contractor shall follow the Sampling and Testing
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    Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in
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    Appendix A shall be read and understood in tandem with the footnotes in Appendix A.
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    3 Inspection and test procedures submitted for approval shall include, but not be limited to, the
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    following:

    (a) inspection/test procedure reference


    (b) references to Clauses of this Specification and other standards along with applicable
    inspection/test levels specified therein
    (c) prerequisites for the given inspection/test
    (d) required tools, equipment
    (e) necessary environmental conditions
    (f) acceptance criteria
    (g) data to be recorded
    (h) reporting forms
    (i) Identification of items inspected and tested.
    (j) Contractors and Engineers Hold, Witness, Surveillance and Record Review Points
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 07: Inspection and Test

    4 Approved procedures and instructions shall be readily available and used by inspection and
    test personnel at the time of inspection or test. All revisions to these procedures and
    instructions shall be approved prior to being used to inspect or test the work. No deviations
    from the approved procedures and instructions shall be allowed without written authorisation
    from the Engineer.

    5 Inspection and testing work shall be performed by personnel designated by the Contractor.
    Such personnel shall not be the same as those performing the work.

    6 The Contractor shall furnish the Engineer with a signed inspection report for each item of
    work inspected and tested. The report shall indicate whether the item of work, material
    and/or equipment complies with all the inspection/test criteria. The Contractor shall submit
    inspection/test results to the Engineer prior to incorporating the item(s) into the work.
    Inspection/test failures shall be reported to the Engineer immediately.

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    7 Inspection and test reports shall, as a minimum, identify the following:

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    (a) inspection/test procedure reference
    (b) name of inspector/tester
    (c) observations/comments
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    (d) specified requirements
    (e) acceptability
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    (f) deviations/non-conformance
    (g) corrective action
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    (h) evaluation of results


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    (i) authorised signature


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    8 The Contractor shall clearly document and identify the inspections and test status of
    all materials and equipment throughout construction. Identification may be by means of
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    stamps, tags, or other control devices attached to, or accompanying, the material or
    equipment.
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    7.1.3 Inspection and Test Status


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    1 The inspection and test status of materials, equipment and construction work shall be
    identified by suitable means, which indicates the conformance or non-conformance of
    materials, equipment and construction work with regard to inspection and tests performed.
    The identification of inspection and test status shall be maintained, as defined in the Quality
    Assurance Plan and/or documented procedures, throughout the course of construction to
    ensure that only materials, equipment and construction work that have passed the required
    inspections and tests are used or installed.

    7.1.4 Inspections by the Engineer during construction

    1 The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and
    Record Review points for the Engineer during construction. The contractor shall prepare,
    document and implement a Request for Inspection system that defines how the Engineer will
    be given sufficient notice to inspect the works in accordance with the Inspection and Test
    Plans.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 07: Inspection and Test

    7.1.5 Inspections by the Engineer during Defects Liability Period

    1 The Engineer will give the Contractor due notice of his intention to carry out any inspections
    during the defects liability period.

    2 The Contractor shall arrange for a responsible representative to be present at the times and
    dates named by the Engineer.

    3 The Contractors representative shall render all necessary assistance and take note of all
    matters to which his attention is directed by the Engineer

    7.1.6 Workmanship

    1 The Contractor shall comply with industry standards except when more restrictive tolerances
    or specified requirements indicate more rigid standards or more precise workmanship.

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    2 Only persons qualified to produce workmanship of the required quality shall perform works

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    3 The Contractor shall comply with manufactures published installation instructions / guides in
    full, including each step in sequence. Should instructions conflict with project documentation,

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    the Contractor shall request clarification from the Engineer before proceeding.
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    7.1.7 Measuring and Test Equipment
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    1 The Contractor shall establish and maintain documented procedures which conform to
    accepted and approved national or international standards to control, calibrate and maintain
    inspection, measuring and test equipment used by the Contractor to demonstrate the
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    conformance of materials, equipment and/or construction work with the requirements of the
    Project Documentation.
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    2 Inspection, measuring and test equipment shall be used in a manner which ensures that the
    measurement uncertainty is known and is consistent with the required measurement
    capability
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    3 The Contractor shall establish a unique identification number for each item of measuring and
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    test equipment. This unique identification number shall be permanently affixed to each item
    of measuring and test equipment
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    4 The Contractor shall ensure that each item of inspection, measuring and test equipment is
    calibrated at intervals recommended by the manufacturer. Valid calibration certificates for
    measuring and testing equipment shall be present and available for inspection during
    inspections and tests.

    5 The Contractor shall establish a log of all measuring and test equipment and record:

    (a) equipment description


    (b) identification number
    (c) date of the last calibration
    (d) date that the next calibration is due.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 07: Inspection and Test

    6 The Contractor shall assess and record the validity of the previous measuring results when
    the equipment is subsequently found not to confirm to requirements. The Contractor shall
    take appropriate action on the equipment and any product affected.

    END OF PART

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 08: Materials

    8 MATERIALS .................................................................................................. 2
    8.1 GENERAL ...................................................................................................... 2
    8.1.1 Plant, Materials, Goods and Workmanship 2
    8.1.2 Handling and Storage of Materials 2
    8.1.3 Identification and Control of Items and Materials 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 08: Materials

    8 MATERIALS

    8.1 GENERAL

    8.1.1 Plant, Materials, Goods and Workmanship

    1 All Plant, materials, goods and workmanship shall be of the respective kinds described in the
    Contract with necessary approvals from the concerned authorities and in accordance with the
    Engineer's instructions and shall be subjected from time to time to such tests as the Engineer
    may direct at the place of manufacture or fabrication or on the Site or at all or any such
    places. The Contractor shall provide such assistance, instruments, machines, labour and
    material as are normally required for examining, measuring and testing any work and the
    quality, weight or quantity of any materials used and shall supply samples of materials before

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    incorporation in the Works for testing as may be selected and required by the Engineer.

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    8.1.2 Handling and Storage of Materials

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    1 The Contractor shall establish procedures for handling and storage of materials and
    equipment.

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    The Contractors storage and handling procedures shall be designed to prevent damage,
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    2
    deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or
    substitution.
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    3 The handling procedures shall address the use, inspection and maintenance of special
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    devices such as crates, boxes, containers, dividers, slings, material handling and
    transportation equipment and other facilities.
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    4 The Contractor shall identify equipment and/or material requiring special handling or storage.
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    8.1.3 Identification and Control of Items and Materials


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    1 The Contractor shall establish control procedures to ensure that equipment and materials are
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    properly used and installed.


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    2 The Contractor shall identify all items and materials so that they are traceable throughout all
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    inspections, test activities, and records. For stored items, the identification method shall be
    consistent with the expected duration and type of storage.

    3 The Contractor shall record equipment and material identifications and ensure that they are
    traceable to the location where they are incorporated into the Works.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 09: Nonconformance Monitoring

    9 NONCONFORMANCE MONITORING .................................................................... 2


    9.1 INTRODUCTION ..................................................................................................... 2
    9.1.1 General 2
    9.1.2 Review and Disposition of Nonconforming Items 2
    9.1.3 Corrective Action 3
    9.1.4 Identification of Nonconforming Items 3
    9.1.5 Acceptance and Approval of Nonconforming items 4
    9.1.6 Nonconformance Records 4

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 09: Nonconformance Monitoring

    9 NONCONFORMANCE MONITORING

    9.1 INTRODUCTION

    9.1.1 General

    1 The Contractor shall ensure that product which does not conform to Specification
    requirements is identified and controlled to prevent its unintended use or delivery. A
    documented procedure shall be established to define the controls and relate responsibilities
    and authorities for dealing with nonconforming product:

    (a) by taking action to estimate the detected nonconformity


    (b) by authorizing its use, release or acceptance under concession by the Engineer

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    (c) by taking action to preclude its original intended use or application

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    (d) by taking action appropriate to the effects, or potential effects, of the nonconformity

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    when nonconformity product is detected after delivery or use has started .

    2 When Conforming product is corrected it shall be subject to re-verification to demonstrate


    conformity to requirements.
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    3 Records of the nature of nonconformities and any subsequent actions taken, including
    concessions obtained by the engineer, shall be maintained.
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    4 The monitoring system shall apply to material and equipment as well as installation and
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    construction which fail to conform to the Contract.


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    5 A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this


    Section and must be used for recording Nonconformance.
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    9.1.2 Review and Disposition of Nonconforming Items


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    1 The responsibility for review and authority for the disposition of nonconforming items shall be
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    defined in the Quality Plan.


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    2 Nonconforming items shall be reviewed in accordance with documented procedures. A


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    nonconforming item may be:

    (a) reworked to meet the specified requirements


    (b) accepted with or without repair if agreed in writing by the Engineer
    (c) re-graded for alternative applications
    (d) rejected or scrapped.

    3 The proposed use or repair of an item which does not conform to the requirements of the
    Project Documentation shall be reported to the Engineer. The description of the
    nonconformity and of repairs shall be recorded to denote the actual condition.

    4 Repaired and/or reworked products shall be inspected in accordance with the Quality
    Assurance Plan and/or documented procedures
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 09: Nonconformance Monitoring

    9.1.3 Corrective Action

    1 The Contractor shall take action to eliminate the causes of nonconformities in order to
    prevent recurrence. Corrective actions shall be appropriate to the effects of the
    nonconformity encountered.

    A documented procedure shall be established to define requirements for:

    (a) Reviewing nonconformities (including Engineer complaints)


    (b) Determining the causes of nonconformities
    (c) Evaluating the need for action to ensure that conformities do not occur
    (d) Determining and implementing actions needed
    (e) Records of the results of action taken and

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    (f) Reviewing the effectiveness of the corrective action taken

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    2 Any corrective or preventive action taken to eliminate the causes of actual or potential
    nonconformities shall be to a degree appropriate to the magnitude of problems and
    commensurate with the risks encountered.

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    The Contractor shall implement and record any changes to the documented procedures for
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    implementing corrective and preventive action.
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    4 The Contractor shall take prompt action to identify the causes of each nonconformance and
    the corrective action necessary prevent recurrence. The results of failure and discrepancy
    report summaries, Contractor evaluations, and any other pertinent applicable data shall be
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    used for determining corrective action. Information developed during construction, tests, and
    inspections that support the implementation of required improvements and corrections shall
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    be used to support the adequacy of corrective action taken.


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    5 The procedures for preventive action shall include:


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    (a) the use of appropriate sources of information such as processes and work operations
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    which affect product quality, concessions, audit results, quality records and service
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    reports to detect, analyse and eliminate potential causes of nonconformities


    (b) determination of the steps needed to deal with any problems requiring preventive
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    action
    (c) initiation of preventive action and application of controls to ensure that it is effective
    (d) ensuring that relevant information on actions taken is submitted for management
    review

    9.1.4 Identification of Nonconforming Items

    1 The Contractor shall clearly identify each nonconforming item with a status tag or other
    distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and
    removing these status tags and identify personnel authorised to remove status tags.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 09: Nonconformance Monitoring

    9.1.5 Acceptance and Approval of Nonconforming items

    1 Acceptance of the Contractors proposed disposition of Nonconforming items should be his


    obtained in writing from the Engineer prior to the undertaking of any remedial works by the
    his Contractor.

    2 Close out of Nonconforming items must be agreed in writing by the Engineer.

    9.1.6 Nonconformance Records

    1 The Contractor shall provide the Engineer with the following information for each
    nonconformance:

    (a) identification of nonconformance


    (b) description of nonconformance

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    (c) evaluation of nonconformance to establish the cause

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    (d) recommended corrective action
    (e) date nonconformance was identified
    (f) date corrective action was completed
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    (g) description of final corrective action.

    2 The Contractor shall establish and maintain a nonconformance log. The log shall contain the
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    following information as a minimum:


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    (a) unique sequential reference number


    (b) date issued
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    (c) originator
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    (d) description of item deemed to be in nonconformance


    (e) description of nonconformance
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    (f) Contractors recommended and final disposition


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    (g) Engineers acceptance of Contractors recommended and final disposition


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    (h) date closed


    (i) remarks, as applicable

    END OF PART
    QCS 2014 Section 03: Ground Investigation Page 1
    Part 01: General

    1 GENERAL ............................................................................................................... 2
    1.1 INTRODUCTION ..................................................................................................... 2
    1.1.1 Scope 2
    1.1.2 References 2
    1.1.3 Definitions 2
    1.2 SUBMITTALS .......................................................................................................... 3
    1.2.1 Programme of Works 3
    1.2.2 Preliminary Logs 3
    1.2.3 Exploratory Hole Logs 4
    1.2.4 Preliminary Laboratory Test Results 5
    1.2.5 Digital Data 5
    1.2.6 Form of Report 5

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    1.2.7 Approval of Report 6

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    1.3 QUALITY ASSURANCE .......................................................................................... 6

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    1.4 GENERAL PROJECT/SITE CONDITIONS .............................................................. 7
    1.4.1 General 7
    1.4.2
    1.4.3
    Working Areas
    Turf and Topsoil ta 7
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    1.4.4 Paved Areas 7
    1.4.5 Paving Slabs and Blocks 7
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    1.4.6 Claims for Damage 8


    1.4.7 Geotechnical and Environmental Personnel 8
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    1.4.8 Location of Exploratory Holes 8


    1.4.9 Ground Elevation of Exploratory Holes 8
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    1.4.10 Exploratory Work 8


    1.4.11 Methods of Investigation 8
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    1.4.12 Safety and Management 9


    1.4.13 Anomalous Conditions 9
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    1.4.14 Surface Water Control 9


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    1.4.15 Photographs 9
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    1.4.16 Facilities for the Engineer 10


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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 01: General

    1 GENERAL

    1.1 INTRODUCTION

    1.1.1 Scope

    1 General requirements and information for the execution of ground investigations.

    2 Related Sections are as follows:

    Section 1 ......... General


    Section 2 ......... Quality Assurance and Quality Control
    Section 4 ......... Foundations and Retaining Structures
    Section 6 ......... Roadworks

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    Section 8 ......... Drainage Works

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    Section 12 ....... Earthworks Related to Buildings

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    1.1.2 References

    1 The following standards and other documents are referred to in this Part:

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    BS 5930......................Code of practice for site investigations
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    BS EN 1997................Ground Investigation and testing
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
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    Purposes
    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
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    Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US
    symposium on rock mechanics. AIME, New York, 1967
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    Code of Practice and Specifications for Road Openings in the Highway issued by the
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    Government.

    1.1.3 Definitions
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    1 Topsoil: the surface layer of earth that contains organic material and can also support
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    vegetation.
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    2 Soil: earthen material not classified herein as topsoil or hard stratum.

    3 Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean
    natural or artificial material, including rock, which cannot be penetrated except by the use of
    chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard
    stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below
    are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

    (a) Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more
    than 300 mm

    (b) Condition (2) a standard penetration resistance test shows a resistance in excess
    of 35 blows/75 mm.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 01: General

    4 Fill: deposits or embankments which have been formed by persons, as distinct from
    geological agencies.

    5 Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the
    purpose of ground investigation.

    6 Boring: hole in earth, excavated by either percussion or auger equipment.

    7 Drilling: any hole in rock, excavated by rotary equipment.

    8 Borehole: exploratory hole excavated by boring or drilling techniques.

    1.2 SUBMITTALS

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    1.2.1 Programme of Works

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    1 The Geotechnical Investigation Contractor shall prepare a programme of works for the

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    investigation which will give a detailed schedule showing proposed time schedule for all
    aspect of the work, details of all plant and equipment to be used in addition to a list of
    personnel who will work on the project.
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    1.2.2 Preliminary Logs

    1 The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory
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    hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or
    trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer
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    in duplicate within seven working days of completion of the explorations to which they refer
    to, and shall contain the information required for the exploratory hole logs.
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    2 Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment
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    (MOE) requirements and/or those of other Government Departments, Ministries and


    Statutory Organizations.
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    3 The Geotechnical Investigation Contractor shall obtain all necessary work permits and
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    security permits prior to commencement of Geotechnical investigation of the site.


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    4 The investigation shall provide detailed information on the nature of the sub-strata, superficial
    deposits and ground water table at the site together with general recommendations for
    designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

    5 The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in


    Section 2.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 01: General

    6 The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table


    1.1.
    Table 1.1: Minimum Depth of Boreholes

    No of floors Depth of Boreholes (m)

    3 or Less 6
    4 8
    5 9
    6 10
    7 12
    8 13
    0.7
    >8 3S

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    Notes:

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    The depth of boreholes is measured from foundation level.
    S is the number of floors.
    For structures small in plan area, exploration should be made at a minimum of three points,

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    unless other reliable information is available in the immediate vicinity. Where a structure
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    consists of a number of adjacent units, one exploration point per unit may suffice.
    For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the
    diameter of the pile at the toe) whichever is greater.
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    For roads, the depth of Boreholes shall be greater than 2m below the proposed formation
    Level.
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    For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:
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    2m below the inverted level;


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    1.5width of excavation.
    2D (D=Diameter or equivalent diameter of the tunnel/underground structure.
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    1.2.3 Exploratory Hole Logs


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    1 The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The
    logs shall include all the information that follows, such information having been updated as
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    necessary in the light of laboratory testing and further examination of samples and cores.

    2 Information for exploratory hole logs:

    Static
    Rotary Pit and and
    Drilling
    Borehole Trench Dynamic
    Probing

    All the designated information


    National grid co-ordinates
    Ground level related to the datum
    Elevation of each stratum referred to the datum ()
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 01: General

    Static
    Rotary Pit and and
    Drilling
    Borehole Trench Dynamic
    Probing
    Description of each stratum in accordance with BS
    5930 and initials of person who carried out the
    ()
    logging (and responsible Supervisor if under
    training)
    Details of groundwater observations ()
    Symbolic legend of strata in accordance with BS
    ()
    5930
    Core recovery as percentage of each core run
    Rock Quality Designation, RQD (Deere et al. 1967)
    _____

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    Note: means information required; () means information required if applicable.

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    1.2.4 Preliminary Laboratory Test Results

    1 Laboratory test results shall be submitted to the Engineer in batches at the completion of
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    each week's testing. Legible photocopies of work sheets are acceptable.
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    1.2.5 Digital Data
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    1 Data from the investigation shall be provided in digital form to the approval of the Engineer.
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    1.2.6 Form of Report


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    1 The report shall comprise of a factual or interpretative or both types of reports as required by
    the Employer or Engineer. Reports shall begin with a cover page showing the name of the
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    Contract and the names of the Employer, Engineer and Geotechnical Investigation
    Contractor. Report pages shall be numbered consecutively.
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    2 The factual report shall contain, as a minimum, the following information:


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    (a) A statement from the Engineer on the purpose and rationale of the investigation.
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    (b) A description of the work carried out, including reference to specification and
    standards adopted and any deviations from them.
    (c) Exploratory hole logs.
    (d) In-situ test records.
    (e) Laboratory test results.
    (f) Plan with locations of exploratory holes.
    (g) Site location plan.
    (h) Geological cross-sections (if appropriate).

    The plans shall be to a stated scale and shall include a north arrow. Additional information
    shall be provided as designated.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 01: General

    3 The interpretative report shall contain the following information:

    (a) A written appraisal of the ground and water conditions.


    (b) Analysis and recommendations as designated.

    When so designated, the Geotechnical Investigation Contractor shall supply the calculations
    and analyses on which recommendations are based.
    1.2.7 Approval of Report

    1 A draft copy of the factual report and the interpretative report shall be submitted to the
    Engineer for approval before submission of the final report.

    1.3 QUALITY ASSURANCE

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    1 Only Geotechnical Investigation Contractors holding a current approval certificate from the

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    Central Materials Laboratory shall be permitted to carry out ground investigations.

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    2 The work shall be carried out in accordance with the relevant British Standards or equivalent.

    3
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    Where specifically designated, all work shall be carried out in accordance with a quality
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    management system established in accordance with Section 2 Quality Assurance and Quality
    Control of the QCS. Records to indicate compliance with quality management shall be made
    available to the Engineer on request.
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    4 The Geotechnical Investigation Contractor shall provide full time professional attendance on
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    site. The professional attendant shall be approved by the Engineer, and shall be responsible
    for the technical direction of all fieldwork.
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    5 The Geotechnical Investigation Contractors geotechnical and environmental personnel


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    employed on the Contract shall be competent to undertake the work required. Categories of
    personnel who may be required by the Contract are as follows:
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    (a) Technician.
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    (b) Graduate Engineer/Geologist/Environmental Scientist.


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    (c) Graduate Engineer/Geologist/Environmental Scientist with at least three years of


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    relevant experience since graduation.


    (d) Professional Engineer/Geologist/Environmental Scientist with at least five years of
    relevant experience.
    (e) Professional Engineer/Geologist/Environmental Specialist with at least ten years of
    relevant experience.

    6 All drillers employed on the Contract shall be experienced and competent in percussion or
    auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent
    drilling supervisor per site shall be permanently on the Site during borehole operations.
    QCS 2014 Section 03: Ground Investigation Page 7
    Part 01: General

    1.4 GENERAL PROJECT/SITE CONDITIONS

    1.4.1 General

    1 Geotechnical Investigation Contractor shall only use access routes to and between
    exploration sites that are approved by the Engineer.

    2 Where the presence of underground services is likely, exploratory holes shall be started by
    means of a hand excavated inspection pit.

    3 In addition to any designated notice, at least one working day's notice of the intended time of
    entry shall be given to the land owner and occupier of the exploration site.

    4 All work shall be carried out with the least possible damage to the Site and its environs.

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    5 All barriers breached or otherwise disturbed during the execution of site operations shall be

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    immediately repaired or replaced to the same standard.

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    6 Working hours shall be restricted to those designated.

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    Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the
    end of each days work.
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    1.4.2 Working Areas
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    1 Operations shall be confined to the minimum area of ground required for the Works. Unless
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    otherwise designated, on completion of each exploration all equipment, surplus material and
    rubbish of every kind shall be cleared away and removed from the Site. Damage to land or
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    property in the vicinity of the exploratory hole and on access routes shall be made good. The
    whole of the Site and any ancillary works shall be left in a clean and tidy condition.
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    1.4.3 Turf and Topsoil


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    1 Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future
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    replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by
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    the operations shall either be removed and stockpiled as above, or otherwise protected from
    damage. After completion of the exploration all topsoil shall be replaced and the Site
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    restored to its original condition.

    1.4.4 Paved Areas

    1 Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the
    minimum extent necessary for each exploration. After completion of the exploration and
    backfill of the excavation, the disturbed subgrade shall be compacted and the paving
    replaced.

    2 Restoration of highway pavement shall be in accordance with the current Code of Practice
    and Specification for Road Openings in the Highway issued by the Government.

    1.4.5 Paving Slabs and Blocks

    1 Paving slabs and blocks shall be removed from the Site, as required for each exploration,
    and stored for reuse.
    QCS 2014 Section 03: Ground Investigation Page 8
    Part 01: General

    2 Contiguous paving slabs and blocks which are liable to be damaged by the operations shall
    either be removed and stored as above or otherwise protected from damage.

    3 After completion of the exploration and backfill of the excavation, the disturbed subgrade
    shall be compacted and the paving slabs and blocks relayed.

    1.4.6 Claims for Damage

    1 Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall
    be reported to the Engineer.

    1.4.7 Geotechnical and Environmental Personnel

    1 In addition to the provision of the designated personnel by the Geotechnical Investigation


    Contractor, the Engineer may specifically require the services of geotechnical and

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    environmental personnel for advice, assistance or preparation of interpretative reports. The

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    form of interpretative reports shall be agreed with the Engineer. Details of the qualifications

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    and experience of the personnel shall be supplied to the Engineer.

    1.4.8 Location of Exploratory Holes

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    The location of each exploratory hole shall be measured from an approved grid co-ordinate
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    system, and shall be accurate to within 1 m, and the position recorded on a plan as
    designated.
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    1.4.9 Ground Elevation of Exploratory Holes


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    1 The elevation of the ground at each exploratory hole shall be established, on the basis of the
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    Qatar National Datum unless otherwise designated or approved by the Engineer, to the
    nearest 0.05 m.
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    1.4.10 Exploratory Work


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    1 The location and depth of each exploratory hole shall be as designated. The Engineer may,
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    after consultation with the Geotechnical Investigation Contractor, vary the location and depth
    of any exploratory hole and the sequence or quantity of in-situ testing depending on the
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    actual ground conditions encountered. When the position of an exploratory hole has been
    varied, the Geotechnical Investigation Contractor shall take all necessary measurements and
    shall inform the Engineer of the revised co-ordinates and ground elevation or other
    measurements required to locate the exploratory hole.

    1.4.11 Methods of Investigation

    1 The Engineer will have the option to require any of the following methods of investigation.
    These options will comprise, but not necessarily be limited to, the following:

    (a) Desk study.


    (b) Geological mapping.
    (c) Topographic survey.
    (d) Aerial photographs.
    or any other methods described in this Section.
    QCS 2014 Section 03: Ground Investigation Page 9
    Part 01: General

    1.4.12 Safety and Management

    1 The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA)
    to all site activities including but not limited to potential hazard, who/what might be harmed,
    control/ recovery measure, responsible personetc.

    2 The presence and nature of known areas of hazardous or contaminated ground are
    designated, based on available records. If evidence of further hazardous or contaminated
    ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform
    the Engineer. If required by the Engineer, the Geotechnical Investigation Contractors work
    plan shall be revised appropriately to take into account the nature and level of contamination
    encountered. Where contaminated land is present or suspected the Geotechnical
    Investigation Contractor shall take the appropriate health and safety precautions as directed
    by the Engineer and where appropriate by the Civil Defence Department of the Government.
    Care shall be taken to avoid contaminating the egress from the Site.

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    3 A method statement indicating the safety procedures to be followed during the investigation

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    of hazardous or contaminated ground shall be provided by the Geotechnical Investigation
    Contractor before beginning the investigation in the hazardous or contaminated ground.

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    Traffic safety and management measures shall be provided, in accordance with the
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    provisions of traffic control of Section 1, General. Where the circumstances of any particular
    case are not designated, proposals for dealing with such situations shall be submitted to the
    Engineer for approval.
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    1.4.13 Anomalous Conditions


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    1 Where anomalous or unexpected features are revealed, the Geotechnical Investigation


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    Contractor shall immediately inform the Engineer.


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    1.4.14 Surface Water Control

    1 Surface water or other water shall be prevented from entering the exploratory hole, except as
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    permitted by the Engineer.


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    1.4.15 Photographs
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    1 Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor
    as designated. Each photograph shall clearly show all necessary details, and shall have its
    scale identified.

    2 A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be
    submitted to the Engineer for his approval, within seven working days of the photography. In
    the event that the photographs are of a quality unacceptable to the Engineer, they shall be
    retaken.

    3 On acceptance of the quality of the photograph, two complete sets of prints of all the
    photographs shall be presented, annotated and submitted in bound volumes, together with
    the original photograph digital format with the factual report.

    4 Particular requirements for photographs of cores and pits and trenches are given in Parts 3
    and 4
    QCS 2014 Section 03: Ground Investigation Page 10
    Part 01: General

    1.4.16 Facilities for the Engineer

    1 When required by the particular contract documentation, facilities to the designated standard
    shall be provided for the use of the Engineer, as described in Section 1.

    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 02: Boreholes

    2 BOREHOLES .......................................................................................................... 2
    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.1.2 References 2
    2.2 BOREHOLES GENERALLY .................................................................................... 2
    2.2.1 Method and Diameter 2
    2.2.2 Addition of Water to the Borehole 3
    2.2.3 Backfilling 3
    2.3 PERCUSSION BORING .......................................................................................... 3
    2.3.1 Hard Stratum or Obstruction in Percussion Boring 3
    2.4 AUGER BORING ..................................................................................................... 3
    2.4.1 Hand Auger 3

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    2.4.2 Continuous Flight Auger Boring 3

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    2.4.3 Hollow Stem Flight Auger 3

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    2.5 ROTARY DRILLING ................................................................................................ 3
    2.5.1 General 3
    2.5.2
    2.5.3
    Drilling Fluid
    Rotary Drilling with Core Recovery ta 4
    4
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    2.5.4 Rotary Drilling without Core Recovery 6
    2.5.5 Backfilling 6
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    2.5.6 Photographs 6
    2.6 BOREHOLES OVERWATER .................................................................................. 6
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 02: Boreholes

    2 BOREHOLES

    2.1 GENERAL

    2.1.1 Scope

    1 Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 ............... General

    Section 4, ........ Foundations and Retaining Structures

    .
    Section 6, ........ Roadworks

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    Section 8, ........ Drainage Works
    Section 12, ...... Earthworks Related to Buildings

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    2.1.2 References

    1
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    The following standards and other documents are referred to in this Part:
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    BS 5930 ......................Code of practice for site investigations.
    BS EN 1997 ................Ground Investigation and testing
    as

    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction


    Purposes
    se

    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


    Engineering Group of the Geological Society Working Party Report The logging of rock cores
    er

    for engineering purposes (1970).


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    2.2 BOREHOLES GENERALLY


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    2.2.1 Method and Diameter


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    et

    1 The method of advancement and the diameter of a borehole shall be such that the boring
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    can be completed and logged to the designated depth, and samples of the designated
    diameter can be obtained, in-situ testing carried out and instrumentation installed.

    2 The following methods may be employed for advancement of a borehole unless otherwise
    designated:

    (a) Percussion boring.


    (b) Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the
    Employer that the SPT values obtained are not effected by disturbance of the soil by
    the auger head, or the presence of material within the hollow stem.).
    (c) Rotary drilling.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 02: Boreholes

    2.2.2 Addition of Water to the Borehole

    1 Jetting with water shall not be used to assist the advance of the borehole, except where
    approved by the Engineer. Where the borehole penetrates below the water table and
    disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

    2.2.3 Backfilling

    1 The Contractor shall backfill boreholes in such a manner as to minimise subsequent


    depression at the ground surface due to settlement of the backfill. In some circumstances,
    grout or special infilling may be required by the Engineer. Where artesian or other water
    conditions make normal backfilling impracticable, the Contractor shall consult and agree with
    the Engineer a procedure for sealing the borehole.

    2.3 PERCUSSION BORING

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    2.3.1 Hard Stratum or Obstruction in Percussion Boring

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    1 In a borehole where percussion boring is employed and a hard stratum or obstruction is
    encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.
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    Should this not penetrate through the hard stratum or obstruction the Contractor shall inform
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    the Engineer, who may instruct the use of one or more of the following:

    (a) continuation of chiselling techniques


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    (b) rotary or other approved drilling until the stratum is penetrated


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    (c) abandonment of the borehole.


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    2.4 AUGER BORING


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    2.4.1 Hand Auger

    1 Hand auger boring may be appropriate in suitable self-supporting strata.


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    2.4.2 Continuous Flight Auger Boring


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    1 Where continuous flight auger boring is used, it shall be carried out under the full-time
    supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c)
    who shall produce, as boring proceeds, a record of the material and groundwater
    encountered.

    2.4.3 Hollow Stem Flight Auger

    1 Where hollow stem flight auger boring is used, the equipment used shall be such as to bore
    and recover samples as designated. Sampling shall be carried out through the hollow stem.

    2.5 ROTARY DRILLING

    2.5.1 General

    1 Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in
    rock, with or without core recovery.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 02: Boreholes

    2.5.2 Drilling Fluid

    1 The drilling fluid shall normally be clean water, air or air mist. However, with the approval of
    the Engineer, drilling muds, additives or foam may be used.

    2.5.3 Rotary Drilling with Core Recovery

    1 Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube
    coring system incorporating a removable inner liner or split tube. The triple tube system may
    be affected by use of a double tube barrel with an approved semi-rigid liner.

    2 Rotary core drilling shall produce cores of not less than the designated diameter throughout
    the core length. Care shall be exercised in the drilling so as to optimise core recovery.

    3 The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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    normally exceed 3 m in length and the core barrel shall be removed from the drill hole as
    often as is required to obtain the best possible core recovery or alternatively the core

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    samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing
    between drill runs.

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    Removal of cores and labelling of liners shall be carried out as follows:
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    (a) All operations entailed in recovering the cores from the ground after completion of
    drilling shall be carried out in a manner such as to minimise disturbance to the cores.
    as

    (b) Core barrels or inner tube in case of wireline shall be held horizontally while the
    innermost liner containing the core is removed without vibration and in a manner to
    se

    prevent disturbance to the core. The core should be rigidly supported at all times while
    it is being extruded and during subsequent handling, and the liner containing the core
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    must not be allowed to flex


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    (c) Immediately after removing the liner the top and bottom shall be marked in indelible
    ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall
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    be cut to the length of the enclosed core. Alternatively, should a metallic split tube be
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    used, the samples shall be placed in half cut PVC pipes sealed with the second half
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    after core samples description with marking of the core run on the PVC tube and the
    core box.
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    (d) Where the length of core recovered from any single core run is such that it cannot be
    accommodated in one channel of the core box, the liner shall be cut to coincide, if
    possible, with existing fractures. The liner either side of the cut shall be marked 'cut'
    and the ends capped as above.
    (e) Each section of liner shall be marked with the contract title, exploratory hole reference
    number, date and the depths of the top and bottom of the drill run.
    (f) Core obtained without a liner and that from within the core catcher but not inside the
    liner shall be wrapped in two layers of plastic cling film and labelled to indicate the
    depth and exploratory hole reference number.

    5 Core boxes, packing, labelling, storing shall be carried out as follows:

    (a) Core boxes shall be soundly constructed and fitted with stout carrying handles,
    fastenings and hinged lids. The total weight of the cores and box shall together not
    exceed 60 kg.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 02: Boreholes

    (b) Cores shall be rigidly and securely packed at the site of drilling and during all
    subsequent handling and storage the cores shall remain packed unless required for
    examination or testing. Cores shall be placed in the box, in their liners where used,
    with the shallowest core to the top left hand corner, the top being considered adjacent
    to the hinged section. Cores from the core catcher shall also be placed in the core
    boxes at the correct relative depth.
    (c) Depth shall be indicated on the core box by durable markers at the beginning and end
    of each drill run. Rigid core spacers shall be used to indicate missing lengths. The
    contract title, exploratory hole reference number and the depth of coring contained in
    each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand
    end of the box and on the inside of the box lid.
    (d) Core boxes containing core shall be kept horizontal and moved and handled with care
    at all times. Cores shall be protected from direct sunlight. At the end of each day's
    work, core boxes shall be stored secure from interference and protected from the

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    weather.

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    6 Cores shall be prepared for examination as follows:

    (a) Cores shall be prepared for examination by the removal of sealing materials and

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    splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut
    lengthways such that at least half the core circumference is exposed. If half PVC is
    qa
    used, care should be taken while removing and replacing the split half.
    (b) Before examination of the core, the Contractor shall photograph the cores. The time
    as

    between beginning preparation and the examination of the prepared and photographed
    cores shall be minimised to prevent loss of moisture from the core samples.
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    (c) Cores shall be examined and described on site by a person meeting the requirements
    of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D
    er

    2488 and the recommendations of the Engineering Group of the Geological Society
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    Working Party Report The logging of rock cores for engineering purpose (1970).

    7 When the examination of the cores has been completed, the Contractor may be required to
    o

    retain separately designated core sub-samples for possible laboratory testing. The Contractor
    it

    shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of
    et

    moisture and sample disturbance. They shall be clearly labelled so that the location, depth
    and origin of the sub-samples can be readily identified. Cores in their liners remaining after
    m

    the designated sub-samples have been removed shall be end-capped and resealed and
    replaced in the original core box location. Rigid spacers shall be placed in the spaces in the
    cores boxes previously occupied by the core sub-samples to prevent movement of adjacent
    cores and these shall be labelled identically to the core sub-samples that they replace. The
    core sub-samples shall be retained in separate core boxes clearly marked to indicate the
    origin of the cores contained within.

    8 The Contractor shall protect all cores and transport them including loading and unloading to

    (a) The Contractor's premises.


    (b) For a number of selected cores, to the designated address.

    9 After submittal of the approved final report, the Contractor shall retain cores, other than those
    delivered to the designated address, for a period of time required by the Engineer. The
    Engineer's written permission shall be obtained before disposal of the cores, but the required
    retention period will normally not exceed three months.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 02: Boreholes

    2.5.4 Rotary Drilling without Core Recovery

    1 Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole
    diameter shall be as designated.

    2 When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other
    cavities or anomalous conditions, drilling shall be under the full-time supervision of a person
    meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a
    systematic record shall be made of the drilling methods, rate of penetration, loss of flushing
    medium, the material penetrated and any cavities or broken ground encountered.

    2.5.5 Backfilling

    1 Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean,

    .
    well graded aggregate. The aggregate size and gradation shall be approved by the Engineer.

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    Under special circumstances grout may be required to backfill the holes. The grout shall
    consist of equal portions by weight of ordinary Portland cement and bentonite mixed by

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    machine or hand to a uniform colour and consistency before placing, with a moisture content
    not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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    a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds.
    qa
    2 Where artesian water conditions or voids make normal grouting impracticable, the Contractor
    shall consult and agree with the Engineer a procedure for sealing the drill hole.
    as

    2.5.6 Photographs
    se

    1 In addition to the requirements of Part 1, the Contractor shall photograph cores where
    required in a fresh condition before logging and ensure that the following criteria are fulfilled:
    er

    (a) A graduated scale in centimetres is provided.


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    (b) Labels and markers are clearly legible in the photograph.


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    (c) A clearly legible reference board identifying the project title, exploratory hole number,
    date, and depth of drill runs shall be included in each photograph.
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    (d) Core boxes are evenly and consistently lit.


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    (e) The length of the core box in each photograph fills the frame.
    (f) The focal plane of the camera and the plane of the core box are parallel.
    (g) The camera is placed in the same position with respect to the core box in every
    photograph.
    (h) The resolution of the camera is not less than 8Mpixels.
    (i) The photograph taken should be in focus along all the core samples length.

    2.6 BOREHOLES OVERWATER

    1 When boreholes are required overwater the method of drilling and sampling shall comply in
    general with the other requirements given in this Section, with the exception of backfilling.

    2 Overwater boreholes shall be undertaken by the use of overwater staging, work over platform
    (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the
    Engineer.
    QCS 2014 Section 03: Ground Investigation Page 7
    Part 02: Boreholes

    3 Control of the elevation related to the borehole/seabed surface or varying stratums shall be
    related to the top of the casing installed. Anchored floating vessels will keep a constant
    record of tidal movement between the vessel and the fixed casing elevation and make any
    allowances necessary.

    4 Boring or drilling operations will cease when the wave height exceeds the designated
    maximum value relating to standing time due to inclement weather, if this item is applicable
    to the Contract under the contract specific documentation.

    5 An accurate method of measuring wave height from trough to crest will be installed on the
    drilling vessel or platform and calibrated and approved by the Engineer before beginning
    drilling operations.

    6 All overwater operations will comply with all local government regulations related to such
    work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at

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    the time.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 03: Pits and Trenches

    3 PITS AND TRENCHES ........................................................................................... 2


    3.1 GENERAL ............................................................................................................... 2
    3.1.1 Scope 2
    3.1.2 References 2
    3.1.3 Quality Assurance 2
    3.2 PITS AND TRENCHES GENERALLY ..................................................................... 2
    3.2.1 Pit and Trench Dimensions 2
    3.2.2 Contaminated Ground 2
    3.2.3 Groundwater 3
    3.2.4 Protection to Pits and Trenches Left Open 3
    3.2.5 Backfilling and Restoration 3
    3.2.6 Photographs 3

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    3.3 INSPECTION PITS .................................................................................................. 3

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    3.3.1 Excavation Method 3

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    3.3.2 Services 3
    3.3.3 Sidewall Stability 4
    3.4
    3.4.1 Excavation Method ta
    TRIAL PITS AND TRENCHES ................................................................................ 4
    4
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    3.4.2 Services 4
    3.4.3 Sidewall Stability 4
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    3.4.4 Trial Pits Examination 4


    3.5 OBSERVATION PITS AND TRENCHES ................................................................. 4
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    3.5.1 Excavation Method 4


    3.5.2 Services 5
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    3.5.3 Sidewall Stability 5


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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 03: Pits and Trenches

    3 PITS AND TRENCHES

    3.1 GENERAL

    3.1.1 Scope

    1 Inspection pits, trial pits and trenches, observation pits and trenches.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General

    Section 1, ....... General

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    Section 4, ....... Foundations and Retaining Structures

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    Section 6, ....... Roadworks
    Section 8, ....... Drainage Works

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    Section 12, ..... Earthworks Related to Buildings.

    3.1.2 References

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    1 The following standards and other documents are referred to in this Part:
    BS 5930 ...................... Code of practice for site investigations
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    BS EN 1997 ................Ground Investigation and testing


    se

    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction


    Purposes
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    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


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    Code of Practice and Specifications for Road Openings in the Highway issued by the
    Government.
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    3.1.3 Quality Assurance


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    1 Trial pits and trenches and observation pits and trenches shall be examined and described
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    by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item
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    (c) and photographed, if required.

    3.2 PITS AND TRENCHES GENERALLY

    3.2.1 Pit and Trench Dimensions

    1 Unless otherwise designated


    2.
    (a) Trial pits and observation pits shall have a minimum base area of 1.5 m
    (b) Trial trenches and observation trenches shall not be less than 1 m wide.

    3.2.2 Contaminated Ground

    1 Ground that is suspected of being contaminated shall be described by an environmental or


    geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5
    Paragraph 5 Item (c).
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 03: Pits and Trenches

    3.2.3 Groundwater

    1 The Contractor shall divert surface water runoff from entering pits and trenches.

    2 Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous
    work if required.

    3.2.4 Protection to Pits and Trenches Left Open

    1 Where pits and trenches are required to be left open and unattended, the Contractor shall
    provide fencing together with all necessary lighting and signing.

    2 Precautions shall be taken to protect the pits and trenches from the adverse effects of
    weather during this period.

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    3.2.5 Backfilling and Restoration

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    1 Pits and trenches shall be backfilled as soon as practicable and reinstated to their original
    condition.

    2
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    The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as
    to minimise any subsequent settlement of the ground surface.
    qa
    3 The use of sand backfill compacted by flooding may be permitted, but this method requires
    as

    the approval of the Engineer.

    4 In paved areas, the pavement shall be restored.


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    3.2.6 Photographs
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    1 In addition to the requirements of Part 1, photographs shall clearly show details of the ground
    ov

    conditions in the pit and trench with any support in place and shall contain a graduated scale.
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    2 Material derived from the excavation shall be photographed, when directed by the Engineer.
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    Artificial lighting shall be used where necessary.


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    3 Unless directed otherwise by the Engineer, three photographs will normally be required at
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    every pit and trench.

    3.3 INSPECTION PITS

    3.3.1 Excavation Method

    1 Inspection pits for the location of underground services shall be excavated by hand to a
    depth of 1.2 m unless otherwise designated.

    2 Hand-operated power tools may be used to assist excavation where necessary.

    3.3.2 Services

    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 03: Pits and Trenches

    3.3.3 Sidewall Stability

    1 Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

    3.4 TRIAL PITS AND TRENCHES

    3.4.1 Excavation Method

    1 Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by
    machine to the required depth to enable visual examination and sampling from outside the pit
    or trench as required.

    2 Where dewatering is required, the pumping equipment used shall be adequate to lower the
    water table to the required level.

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    3.4.2 Services

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    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.

    3.4.3 Sidewall Stability


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    1 Excavations deeper than 1.2 m shall be braced if necessary.
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    3.4.4 Trial Pits Examination


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    1 All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or
    ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society
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    Working Party.
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    2 Disturbed samples shall be obtained from the trial pits for laboratory testing and geological
    description purposes. The samples shall be taken to be representative of the actual site
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    conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories
    for examination and testing.
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    3 Color photographs shall be taken for each excavated trial pit with a metric scale laid into the
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    pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

    3.5 OBSERVATION PITS AND TRENCHES

    3.5.1 Excavation Method

    1 Observation pits and trenches shall be excavated by hand or machine and shall be
    adequately supported to enable personnel to enter safely and to permit in-situ examination,
    soil sampling and testing as required. In areas where dewatering is required, the equipment
    and methods proposed must be approved by the Engineer before beginning the work.

    2 All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or
    ASTM D 2488.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 03: Pits and Trenches

    3 Disturbed samples shall be obtained for laboratory testing and geological description
    purposes (if required). The samples shall be taken to be representative of the actual site
    conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories
    for examination and testing.

    4 Color photographs shall be taken for each excavated pit with a metric scale laid into the pit
    after cleaning it, indicating the pits details such as trial pit number, date and depth.

    3.5.2 Services

    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.

    3.5.3 Sidewall Stability

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    1 Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 04: Soil Sampling

    4 SOIL SAMPLING ..................................................................................................... 2


    4.1 GENERAL ............................................................................................................... 2
    4.1.1 Scope 2
    4.1.2 References 2
    4.2 SAMPLING GENERALLY ........................................................................................ 2
    4.2.1 Sampling and Testing Frequency 2
    4.2.2 Recording depths of samples 3
    4.2.3 Description of samples 3
    4.2.4 Labelling, Protection and Transportation of Samples 3
    4.2.5 Retention and Disposal of Samples 3
    4.3 SOIL SAMPLES....................................................................................................... 3
    4.3.1 Small Disturbed Samples 3

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    4.3.2 Bulk Disturbed Samples 3

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    4.3.3 Open Tube and Piston Samples 4

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    4.3.4 Standard Penetration Test Samples 4
    4.4 GROUNDWATER SAMPLES .................................................................................. 4
    4.5 SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND
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    LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4
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    4.6 GAS SAMPLING...................................................................................................... 5
    4.7 SPECIAL SAMPLING .............................................................................................. 5
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 04: Soil Sampling

    4 SOIL SAMPLING

    4.1 GENERAL

    4.1.1 Scope

    1 Taking of samples of soil, groundwater, gas and contaminants. Sample handling,


    transportation, storage, retention and disposal.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General
    Part 2, .............. Boreholes

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    Part 3, .............. Pits and Trenches.

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    4.1.2 References

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    1 The following documents are referred to in this Part:

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    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
    qa
    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
    as

    BS 5930 ......................Code of practice for site investigations


    BSI DD 175 ..............Code of practice for the identification of potentially contaminated land
    se

    and its investigation (draft for development).


    BS EN 1997--- ............ Ground Investigation and testing
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    ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in
    construction, Part 4, Guidelines for the safe investigation by drilling of landfills and
    contaminated land, Thomas Telford, (1993).
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    et

    4.2 SAMPLING GENERALLY


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    4.2.1 Sampling and Testing Frequency

    1 The frequency of sampling and in-situ testing is dependent on the ground conditions. In the
    absence of designated requirements the intervals observed shall be as follows:

    (a) in boreholes
    (i) first open tube sample (generally in clay soils) or standard penetration test
    (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth,
    thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

    (ii) small disturbed samples shall be taken from the topsoil, at each change in soil
    (iii) type or consistency and midway between successive open tube samples or
    SPTs.
    (iv) Bulk disturbed samples shall be taken of each soil type.
    (b) in pits and trenches
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 04: Soil Sampling

    (i) Small disturbed samples shall be taken of the topsoil, at each change in soil
    type or consistency and between successive bulk disturbed samples.
    (ii) Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one
    large bulk disturbed sample of each soil type.

    4.2.2 Recording depths of samples

    1 The depths below ground level at which samples are taken shall be recorded. For open tube
    and piston samples the depth to the top and bottom of the sample, and the length of sample
    obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

    4.2.3 Description of samples

    1 All samples shall be examined and described by a geotechnical person meeting the

    .
    requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930.

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    Samples of suspected contaminated ground and leachate shall be described by an
    environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5,

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    Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell
    with reference to specific inclusions.

    4.2.4 Labelling, Protection and Transportation of Samplesta


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    1 Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater,
    leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a
    as

    red label.
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    2 Samples shall be protected from direct heat and sunlight.


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    3 Samples shall be transported to the Contractor's premises. Where required by the Engineer,
    selected samples shall be delivered to the designated address.
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    4.2.5 Retention and Disposal of Samples


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    1 Samples shall be kept for the designated period after submission of the approved final report.
    et

    This period shall not exceed three months, unless specifically designated otherwise. The
    Contractor shall ultimately dispose of all samples other than those delivered to the
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    designated address.

    4.3 SOIL SAMPLES

    4.3.1 Small Disturbed Samples

    1 Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately
    in airtight containers, which they should sensibly fill.

    4.3.2 Bulk Disturbed Samples

    1 Bulk disturbed samples shall be representative of the zone from which they have been taken.

    2 Normal bulk disturbed samples shall weigh not less than 10 kg.

    3 Large bulk disturbed samples shall weigh not less than 30 kg.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 04: Soil Sampling

    4.3.3 Open Tube and Piston Samples

    1 Open tube and piston samples shall be taken using the sampling equipment and procedures
    as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

    2 Before an open tube or piston sample is taken, the bottom of the hole shall be carefully
    cleared of disturb materials and where a casing is being used the sample shall be taken
    below the bottom of the casing. Following a break in the work exceeding one hour, the
    borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

    3 Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be
    cleaned out for the full depth to which the sampling tube has penetrated and the recovered
    soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of
    the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful

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    the Contractor shall agree with the Engineer as to alternative means of sampling.

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    4 The samples shall be sealed immediately to preserve their natural moisture content and in

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    such a manner as to prevent the sealant from entering any voids in the sample.

    5 Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed
    sample.
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    4.3.4 Standard Penetration Test Samples
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    1 When a standard penetration test (SPT) is made, the sample from the split barrel sampler
    shall be retained as a small disturbed sample.
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    4.4 GROUNDWATER SAMPLES


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    1 Groundwater samples shall be taken from each exploratory hole where groundwater is
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    encountered. Where more than one groundwater level is found, each one shall be sampled
    separately. Where water has been previously added, the hole shall be bailed out before
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    sampling so that only groundwater is present. The sample volume shall be not less than 0.25
    it

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    4.5 SAMPLES OF SUSPECTED CONTAMINATED GROUND,


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    GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

    1 Samples of suspected contaminated ground, groundwater and leachate shall be taken in


    accordance with DD 175 and the SISG publication under the supervision of an environmental
    or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

    2 The size and type of sample and container, method of sampling and time limitations for
    carrying out specific analyses shall be commensurate with the range of analyses to be
    carried out or as designated.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 04: Soil Sampling

    4.6 GAS SAMPLING

    1 Samples of gas for chromatographic analysis shall be obtained from exploratory holes or
    standpipes in accordance with DD 175 and the SISG publication. The sampling method shall
    relate to the volume of gas available and the type of laboratory analysis. The sampler
    receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas
    bombs.

    4.7 SPECIAL SAMPLING

    1 The Engineer may require special sampling. This work will normally require supervision on
    site by a geotechnical person and shall be carried out in accordance with BS 5930 or as
    designated.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5 IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2


    5.1 GENERAL ............................................................................................................... 2
    5.1.1 Scope 2
    5.1.2 References 2
    5.2 TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2
    5.2.1 Testing 2
    5.2.2 Instrumentation and Monitoring 3
    5.3 TESTS ..................................................................................................................... 3
    5.3.1 Tests in accordance with BS 1377 or BS EN 1997 3
    5.3.2 Tests in accordance with BS 5930 4
    5.3.3 Geophysical Methods of Investigation 4
    5.3.4 Special In-Situ Testing 4

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    5.3.5 Hand Penetrometer and Hand Vane for Shear Strength 5

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    5.3.6 Self-boring Pressuremeter 5

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    5.4 INSTRUMENTATION AND MONITORING .............................................................. 6
    5.4.1 Groundwater 6
    5.4.2
    5.4.3
    Installation of Standpipes and Piezometers
    Installation of Gas Monitoring Standpipes ta 6
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5 IN-SITU TESTING, INSTRUMENTATION AND MONITORING

    5.1 GENERAL

    5.1.1 Scope

    1 Testing of soils in place, and provision of instrumentation and monitoring of groundwater and
    subsurface gases.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 ............... General
    Part 2 ............... Boreholes

    .
    Part 3 ............... Pits and Trenches.

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    5.1.2 References

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    1 The following standards and other documents are referred to in this Part:

    ta
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
    qa
    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
    BS 1377......................Methods of tests for soils for civil engineering purposes
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    BS 5930......................Code of practice for site investigations


    BS 7022......................Geophysical logging of boreholes for hydrogeological purposes
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    BS EN 1997................Ground Investigation and testing


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    The Geological Society Engineering Group Working Party Report on Engineering


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    Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.


    Clarke B.G. and Smith A., A model specification for radial displacement measuring
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    pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.


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    5.2 TESTING, INSTRUMENTATION AND MONITORING GENERALLY


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    5.2.1 Testing

    1 The following information shall be submitted for each test record to be included in the daily
    report, preliminary log and factual report:

    (a) Date of test.


    (b) Project name, exploratory hole number and location.
    (c) Depth and location of test or depths covered by test.
    (d) Information on water levels in exploratory hole during testing.
    (e) Original ground level at test site.
    (f) Soil type and description as identified from the sample.

    2 All results shall be reported in SI units.


    QCS 2014 Section 03: Ground Investigation Page 3
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    3 Where load, displacement or other measuring equipment is used which necessitates regular
    calibration, then this shall be carried out in accordance with the relevant standard (the
    preferred method) or the manufacturer's instructions, by a calibration service approved by the
    Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall
    be supplied to the Engineer prior to commencing work and when otherwise requested.

    5.2.2 Instrumentation and Monitoring

    1 The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected
    by a cover. The type of protective cover shall be approved by the Engineer.

    2 When instructed by the Engineer, the Contractor shall install a protective fence around the
    top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle
    iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the
    climate of Qatar or a fence as a agreed upon with the Engineer.

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    3 Daily readings of depths to water in groundwater monitoring standpipes and piezometers

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    shall be made by the Contractor, with an instrument approved by the Engineer.

    4 Where the presence of gas is suspected or when directed by the Engineer, gas

    ta
    measurements, using an approved in-situ meter, shall be made by the Contractor during
    construction of exploratory holes and in gas monitoring standpipes. The depth to water and
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    barometric pressure shall be measured immediately after each gas measurement.
    as

    5 Unless otherwise designated, piezometers, and standpipes protection shall not be removed
    from the site.
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    6 Other instrumentation and monitoring shall be carried out as designated.


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    5.3 TESTS
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    5.3.1 Tests in accordance with BS 1377 or BS EN 1997


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    1 The following in-situ tests shall be carried out and reported in accordance with BS 1377 or
    it

    BS EN 1997:
    et

    (a) in-situ density by


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    (i) Small pouring cylinder method.


    (ii) Large pouring cylinder method.
    (iii) Water replacement method.
    (iv) Core cutter method.
    (v) Nuclear method.
    (b) Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise
    designated
    (c) Dynamic probing (DPH or DPSH).
    (d) Standard penetration test (SPT).
    (e) Plate loading test.
    (f) Shallow pad maintained load test.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    (g) California bearing ratio (CBR).


    (h) Vane shear strength.
    (i) Apparent resistivity of soil.
    (j) Redox potential.
    (k) Pressurementer or Self-boring Pressuremeter (PMT)
    (l) Pocket Penetrometer.

    5.3.2 Tests in accordance with BS 5930

    1 The following in-situ tests shall be carried out where applicable and reported in accordance
    with BS 5930:
    (a) Constant head permeability test.

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    (b) Variable head permeability test.

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    (c) Packer permeability test.

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    5.3.3 Geophysical Methods of Investigation

    1 Geophysical testing shall be carried out as designated. The Contractor shall submit to the

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    Engineer a full description of equipment and procedure for each geophysical method
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    required.

    2 The equipment and procedure, and information to be submitted for the following geophysical
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    methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological


    Society Engineering Group Working Party Report on Engineering Geophysics:
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    (a) electrical resistivity method


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    (b) seismic refraction and reflection method


    (c) magnetic method
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    (d) gravity method


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    (e) electromagnetic method


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    (i) Ground conductivity.


    (ii) Transient electromagnetic.
    (iii) Ground probing radar (optional).
    (f) Borehole geophysical logging.
    (g) Cross-hole seismic method.
    (h) Multi Channel Analysis of Surface Waves (MASW)
    (i) Refraction Microtremor (ReMi)

    5.3.4 Special In-Situ Testing

    1 Special in-situ testing shall be carried out as designated.

    2 The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for
    the execution of inspection tests.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    3 Inspection tests shall be decided as directed by the Engineer. These tests shall include but
    not limited to those in Table 3.2.

    Table 3.2: Quality Assurance Tests for Completed Work

    Recommended Test per Layer

    Shallow Fill Deep Fill


    (trench or test pit) (boreholes)
    In-situ CBR Field density

    Plate load Test Layer Thickness

    Field density DCP Test

    Layer Thickness SPT

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    DCP Test Pressure meter

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    Large Scale Loading

    5.3.5 Hand Penetrometer and Hand Vane for Shear Strength


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    1 Hand penetrometer and hand vane tests shall be carried out where required to give a
    preliminary estimate of undrained shear strength of the soil tested.
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    2 Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with
    2
    stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.
    se

    The scale shall be suitably graduated. The procedure for the test shall be in accordance with
    the manufacturer's instructions. Both unconfined compressive strength and estimated shear
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    strength shall be reported for the soil tested.


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    3 Hand vane equipment shall be of an approved proprietary make with stainless steel vanes
    having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be
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    suitably graduated. The procedure for test shall be in accordance with BS 5930 and the
    it

    manufacturer's instructions. Peak shear strength and residual shear strength shall be
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    recorded.
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    4 The reported shear strengths for the hand penetrometer and handvane shall be the average
    of 3 tests in close proximity. Tests giving inconsistent results shall be reported and
    comments on the relevance of the tests noted.

    5.3.6 Self-boring Pressuremeter

    1 The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP)
    unless otherwise designated. The instruments, calibration, operator, installation, testing
    procedure, on-site data processing and analysis, information to be submitted, report data
    processing and analysis and information to be submitted in the report shall be as described
    by Clarke and Smith (1992) and as designated..
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5.4 INSTRUMENTATION AND MONITORING

    5.4.1 Groundwater

    1 When groundwater is encountered in exploratory holes, the depth from ground level of the
    point of entry shall be recorded together with depth of any casing. Exploratory hole
    operations shall be stopped and the depth from ground level to water level recorded with an
    approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the
    period of 20 minutes the water level is still rising, this shall be recorded together with the
    depth to water below ground level, unless otherwise instructed by the Engineer, and the
    exploratory hole shall then be continued. If casing is used and this forms a seal against the
    entry of groundwater, the Contractor shall record the depth of casing at which no further entry
    or only insignificant infiltration of water occurred.

    .
    2 Water levels shall be recorded as required by the Contract and at the beginning and end of

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    each shift. On each occasion when groundwater levels are recorded, the depth of the
    exploratory hole, the depth of any casing and the time shall also be recorded.

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    3 Where artesian conditions are encountered, the Contractor shall immediately inform the

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    Engineer and agree a method for dealing with the conditions.
    qa
    5.4.2 Installation of Standpipes and Piezometers

    1 Standpipes for monitoring groundwater levels and changes in groundwater levels shall be
    as

    installed in exploratory holes, as instructed by the Engineer. They shall be to the designated
    form and detail, and appropriate dimensions and depths shall be recorded at the time of
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    installation.
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    2 Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be


    installed as instructed by the Engineer. They shall be to the designated form and detail, and
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    appropriate dimensions. The installation details of the standpipe piezometers shall be


    recorded.
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    3 The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type
    et

    described in BS 5930 or as designated by the Engineer.


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    5.4.3 Installation of Gas Monitoring Standpipes

    1 Standpipes for monitoring gas concentration in exploratory holes shall be installed as


    instructed by the Engineer. Warning signs or other safety measures required by the Civil
    Defence Department of the Government shall be complied with. Standpipes shall be of the
    designated form and detail. All dimensions and depths shall he recorded at the time of
    installation.

    END OF PART
    QCS 2014 Section 03: Ground Investigation Page 1
    Part 06: Laboratory Testing

    6 LABORATORY TESTING ........................................................................................ 2


    6.1 GENERAL ............................................................................................................... 2
    6.1.1 Scope 2
    6.1.2 References 2
    6.2 SCHEDULE OF TESTS ........................................................................................... 2
    6.3 TESTING PROCEDURES ....................................................................................... 3
    6.3.1 General 3
    6.3.2 Geotechnical Testing on Contaminated Samples 3
    6.3.3 Soil Testing 3
    6.3.4 Rock Testing 3
    6.4 CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4
    6.4.2 Laboratory Testing On Site 6

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    6.4.3 Special Laboratory Testing 6

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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 06: Laboratory Testing

    6 LABORATORY TESTING

    6.1 GENERAL

    6.1.1 Scope

    1 Geotechnical tests and testing procedures carried out in the laboratory or, when designated,
    on site.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General
    Part 3, .............. Soil Sampling

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    Section 6, ........ Roadworks
    Section 8, ........ Drainage Works

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    Section 12, ...... Earthworks Related to Buildings

    6.1.2 References

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    1 The following standards and other documents are referred to in this Part:
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
    as

    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


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    ASTM SP 402.............Special Technical Publications No. 402


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    BS 1377 ......................Methods of tests for soils for civil engineering purposes


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    BS 1881 ......................Analysis of hardened concrete


    BS 812 ........................Testing aggregates
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    BS EN 1997--------- .....Ground Investigation and testing


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    et

    Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for
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    Rock Mechanics Suggested Methods. 1981. Pergamon Press.


    C2 through C25 and C27 through C31, Methods for examination of waters and associated
    materials, HMSO
    IRSM Commission on Testing Methods. Suggested method for determining Point Load
    Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22,
    51-60 (1985).

    6.2 SCHEDULE OF TESTS

    1 The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be
    necessary to designate additional testing after the results of the original tests are available.
    Unless otherwise agreed, testing schedules are to be provided within six working days of the
    receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the
    Engineer within six working days from the receipt of the approved testing schedule if a
    sample referred to in the schedule is not available for testing.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 06: Laboratory Testing

    6.3 TESTING PROCEDURES

    6.3.1 General

    1 Where applicable, all preparation, testing and reporting shall be in accordance with the
    relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are
    not covered by these Standards, they shall be performed in accordance with the procedures
    in the references or as designated.

    2 Calibration of load-displacement or other measuring equipment shall be carried out in


    accordance with the relevant standard (the preferred method) or the manufacturers
    instructions by a calibration service approved by the Central Materials Laboratory. Evidence
    of current calibrations shall be supplied to the Engineer.

    .
    6.3.2 Geotechnical Testing on Contaminated Samples

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    1 Where geotechnical testing is required on samples of suspected contaminated material,

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    indicative chemical testing shall be carried out and a safe method of working approved by the
    Engineer before any such work is started. It should be noted that this may include but is not
    limited to the safe storage, transportation and handling of all suspect material.
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    6.3.3 Soil Testing

    1 Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards
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    unless otherwise designated.


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    6.3.4 Rock Testing


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    1 Rock testing shall be carried out and reported in accordance with the following references
    and as designated:
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    (a) Classification.
    (i) Natural water content - Brown (1981).
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    (ii) Porosity/density - Brown (1981).


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    (iii) Void index - Brown (1981).


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    (iv) Carbonate content - BS 1881.


    (v) Petrographic description -Brown (1981).
    (b) Durability.
    (i) Slake durability index - Brown (1981).
    (ii) Soundness by solution of magnesium sulphate - BS 812.
    (c) Hardness.
    (i) Shore sclerometer -Brown (1981).
    (ii) Schmidt rebound hardness - Brown (1981).
    (d) Aggregates.
    (i) Aggregate crushing value - BS 812.
    (ii) Ten percent fines - BS 812.
    (iii) Aggregate impact value - BS 812.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 06: Laboratory Testing

    (iv) Aggregate abrasion value - BS 812.


    (v) Polished stone value - BS 812.
    (vi) Aggregate frost heave - BS 812.
    (e) Strength.
    (i) Uniaxial compressive strength - Brown (1981).
    (ii) Deformability in uniaxial compression -Brown (1981).
    (iii) Tensile strength-Brown (1981).
    Direct tensile strength.
    Indirect tensile strength by the Brazilian method.
    (iv) Undrained triaxial compression without measurement of porewater pressure-
    Brown (1981).
    (v) Direct shear strength - Brown (1981).

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    (vi) Swelling pressure - Brown (1981).

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    Swelling pressure index under conditions of zero volume change.
    Swelling strain index for a radially confined specimen with axial surcharge.
    Swelling strain developed in an unconfined rock specimen.
    (vii)
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    Point load test - IRSM Commission on Testing Methods (1985).
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    (f) Geophysical.
    (i) Seismic velocity-Brown (1981).
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    6.4 CHEMICAL TESTING FOR CONTAMINATED GROUND


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    1 Chemical testing for contaminated ground shall be carried out and reported in accordance
    with the following references and as designated:
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    (a) Primary contaminants in soil.


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    (i) Arsenic total - C4.


    (ii) Cadmium total - C2.
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    (iii) Chromium total - C2.


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    (iv) hexavalent chromium (undertaken if total chromium content >25 mg/kg dry
    et

    Mass) -C2.
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    (v) Lead total - C2.


    (vi) Mercury total - C3.
    (vii) Selenium total - C4.
    (viii) Boron, water-soluble - C5.
    (ix) Copper total - C2.
    (x) Nickel total - C2.
    (xi) Zinc total - C2.
    (xii) Cyanide total (alkali extraction methods) - C6.
    (xiii) Cyanide complex - C6.
    (xiv) Cyanide free - C6.
    (xv) Thiocyanate - C6.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 06: Laboratory Testing

    (xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods
    shall follow alkali extraction.)
    (xvii) Phenols total - C7.
    (xviii) Sulphide - C8.
    (xix) Sulphate - total, acid, soluble - C9.
    (xx) Sulphate - water soluble, 2 : 1 extract - C9.
    (xxi) Sulphur free - C10.
    (xxii) PH value - C9.
    (xxiii) Toluene extractable matter - Cl1.
    (xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter>
    2000 g/kg dry mass of soil) - C12.

    .
    (xxv) Asbestos. Asbestos content determination shall be carried out by visual

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    examination and polarised light microscopy.

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    (b) Secondary contaminants in soil.

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    (i) Antimony total - C13.
    (ii) Barium total - C13.
    (iii) Beryllium total - C15. ta
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    (iv) Vanadium total - C13.
    (v) Cyclohexane extractable matter - C14.
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    (vi) Freon extractable matter - C15.


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    (vii) Mineral oils - C31.


    (viii) Chloride - C9.
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    (c) Contaminants in water.


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    (i) Arsenic - C4.


    (ii) Cadmium - C2 and C23.
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    (iii) Chromium - C2 and C24.


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    (iv) Hexavalent chromium - C2.


    et

    (v) Lead - C2 and C25.


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    (vi) Mercury - C3.


    (vii) Selenium - C4.
    (viii) Boron - C5 and C6.
    (ix) Copper - C2 and C27.
    (x) Nickel - C2 and C28.
    (xi) Zinc - C2 and C29.
    (xii) Cyanide total - C6.
    (xiii) Cyanide complex - C6.
    (xiv) Cyanide free - C6.
    (xv) Thiocyanate - C6.
    (xvi) Phenols total - C7.
    (xvii) Sulphide - C8.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 06: Laboratory Testing

    (xviii) Sulphate - C9.


    (xix) Sulphur free - C10.
    (xx) PH value - C9.
    (xxi) Polyaromatic hydrocarbons - C 12.
    (xxii) Antimony-C13.
    (xxiii) Barium-C13.
    (xxiv) Beryllium-C15.
    (xxv) Vanadium - C 13.
    (xxvi) Chloride - C9.
    (xxvii) Ammoniacal nitrogen - C16.
    (xxviii) Nitrate nitrogen - Cl7.

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    (xxix) Chemical oxygen demand - C18.

    .l.
    (xxx) Biochemical oxygen demand - C19.

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    (xxxi) Total organic carbon - C20.
    (xxxii) Volatile fatty acids - C21.
    (xxxiii) Iron - C22.
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    qa
    (xxxiv) Manganese - C22.
    (xxxv) Calcium - C31.
    as

    (xxxvi) Sodium - C31.


    (xxxvii) Magnesium - C31.
    se

    (xxxviii) Potassium - C21.


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    (d) Constituents of gas samples.


    ov

    (i) Carbon dioxide - C30.


    (ii) Hydrogen - C30.
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    (iii) Hydrogen sulphide - C30.


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    (iv) Methane - C30.


    et

    (v) Nitrogen - C30.


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    (vi) Oxygen - C30.


    (vii) Ethane- C30.
    (viii) Propane- C30.
    (ix) Carbon monoxide - C30.

    6.4.2 Laboratory Testing On Site

    1 When designated, tests listed under laboratory testing shall be carried out on site.

    6.4.3 Special Laboratory Testing

    1 When designated, special laboratory testing shall be carried out.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 01: General Requirements for Piling Work

    1 GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2


    1.1 GENERAL ............................................................................................................... 2
    1.1.1 Scope 2
    1.1.2 References 2
    1.1.3 General Contract Requirements 2
    1.1.4 Submittals 3
    1.1.5 Records 3
    1.2 GROUND CONDITIONS ......................................................................................... 3
    1.2.1 Ground Investigation Reports 3
    1.2.2 Unexpected Ground Conditions 4
    1.3 MATERIALS AND WORKMANSHIP........................................................................ 4
    1.3.1 General 4

    .
    1.3.2 Sources of Supply 4

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    1.3.3 Rejected materials 5

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    1.4 INSTALLATION TOLERANCES .............................................................................. 5
    1.4.1 Setting Out 5
    1.4.2
    1.4.3
    Position
    Verticality ta 6
    6
    qa
    1.4.4 Rake 6
    1.4.5 Tolerance Variations 6
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    1.4.6 Forcible Corrections to Pile 6


    1.5 NUISANCE AND DAMAGE ..................................................................................... 6
    se

    1.5.1 Noise and Disturbance 6


    1.5.2 Damage to Adjacent Structures 7
    er

    1.5.3 Damage to Piles 7


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    1.5.4 Temporary Support 7


    1.6 SAFETY .................................................................................................................. 7
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    1.6.1 General 7
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    1.6.2 Life-Saving Appliances 7


    et

    1.6.3 Driving 7
    m
    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 01: General Requirements for Piling Work

    1 GENERAL REQUIREMENTS FOR PILING WORK

    1.1 GENERAL

    1.1.1 Scope

    1 This Part is concerned with all works associated with installation of piles by any of the
    recognised techniques.

    1.1.2 References

    1 The following standards and codes of practice are referred to in this Part:
    BS 5228......................Noise control on construction and open sites

    l .
    Part I, Code of practice for basic information and procedures for noise

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    control

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    Part IV, Code of practice for noise and vibration control applicable to
    piling operations
    BS 8008......................Safety precautions and procedures for the construction and descent of
    ta
    machine-bored shafts for piling and other purposes
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    BS EN 1997................Eurocode 7, Geotechnical Design.
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    1.1.3 General Contract Requirements


    se

    1 The following matters, where appropriate, are described in the contract specific
    er

    documentation for the Works:


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    (a) general items related to Works


    (i) Nature of the Works.
    o

    (ii) Classes of loads on piles.


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    et

    (iii) Contract drawings.


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    (iv) Other works proceeding at the same time.


    (v) Working area.
    (vi) Order of the Works.
    (vii) Datum.
    (viii) Offices for the Engineer's Representative.
    (ix) Particular facilities and attendance items where not included in this section.
    (x) Details of soil investigation reports.

    (b) specific items related to particular type of pile


    (i) Soil sampling, laboratory testing and in-situ soil testing.
    (ii) Designed concrete or grout mixes, grades of concrete or grout, type of cement
    and aggregate, grout or concrete admixtures, concreting of piles.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 01: General Requirements for Piling Work

    (iii) Grades and types of reinforcement and prestressing tendons.


    (iv) Pile dimensions, length and marking of piles.
    (v) Type and quality of pile shoe/splice.
    (vi) Type and quality of permanent casing.
    (vii) Specified working loads.
    (viii) Sections of proprietary types of pile, grades of steel, minimum length to be
    supplied, thickness of circumferential weld reinforcement.
    (ix) Surface preparation, types and thickness of coatings.
    (x) Test piles, driving resistance or dynamic evaluation and penetration.
    (xi) Detailed requirements for driving records.

    .
    (xii) Acceptance criteria for piles under test.

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    .l.
    (xiii) Disposal of cut-off lengths.

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    (xiv) Preboring.

    1.1.4 Submittals

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    1 The Contractor shall supply for approval all relevant details of the method of piling and the
    plant he proposes to use. Any alternative method to that specified shall be subject to
    approval.
    as

    2 The Contractor shall submit to the Engineer on the first day of each week, or at such longer
    se

    periods as the Engineer may from time to time direct, a progress report showing the current
    rate of progress and progress during the previous period on all important items of each
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    section of the Works.


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    3 The Contractor shall inform the Engineer each day of the intended programme of piling for
    the following day and shall give adequate notice of his intention to work outside normal hours
    and at weekends.
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    1.1.5 Records
    et

    1 The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation
    m

    of each pile and shall submit two signed copies of these records to the Engineer not later
    than noon of the next working day after the pile is installed. The signed records will form a
    record of the work. Any unexpected driving or boring conditions shall be noted briefly in the
    records.

    1.2 GROUND CONDITIONS

    1.2.1 Ground Investigation Reports

    1 Factual information and reports on site investigations for the Works and on the previous
    known uses of the Site will be provided by the Engineer where they exist as part of the
    specific contract documentation. However, even if a full report is given, including
    interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any
    opinions or conclusions which may be given in the reports.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 01: General Requirements for Piling Work

    2 Before the start of work the Contractor shall be given a copy of any subsequent information
    which may have been obtained relating to the ground conditions and previous uses of the
    Site.

    1.2.2 Unexpected Ground Conditions

    1 The Contractor shall report immediately to the Engineer any circumstance which indicates
    that in the Contractor's opinion the ground conditions differ from those reported in or which
    could have been inferred from the site investigation reports or test pile results.

    1.3 MATERIALS AND WORKMANSHIP

    1.3.1 General

    1 All materials and workmanship shall be in accordance with the appropriate British Standards,

    l .
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    codes of practice and other approved standards current at the date of tender except where
    the requirements of these standards or codes of practice are in conflict with this Section in

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    which case the requirements of this Section shall take precedence.

    1.3.2 Sources of Supply

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    qa
    1 The sources of supply of materials shall not be changed without prior approval.

    Table 1.1
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    Records to be Kept (Indicated by an Asterisk)


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    Driven steel, precast

    Driven cast-in-place

    Bored cast-in-place
    concrete and steel

    auger concrete or
    Driven segmental

    Continuous flight
    concrete piles
    concrete piles

    concrete piles
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    sheet piles

    grout piles
    Data
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    it o

    Contract * * * * *
    et

    Pile reference number (location) * * * * *


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    Pile type * * * * *
    Nominal cross-sectional dimensions or diameter * * * * *
    Nominal diameter of underream/base - - - * -
    Length of preformed pile * * - - -
    Standing groundwater level from direct observation or given site
    - - * * *
    investigation data.

    Date and time of driving, redriving or boring * * * * *

    Date of concreting - - * * *
    Ground level/sea bed level at pile position at commencement of
    * * * * *
    installation of pile (commencing surface)
    Working elevation of pile driver * * * * *
    Depth from ground level at pile position to pile tip * * * * *
    Tip elevation * * * * *
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 01: General Requirements for Piling Work

    Driven steel, precast

    Driven cast-in-place

    Bored cast-in-place
    concrete and steel

    auger concrete or
    Driven segmental

    Continuous flight
    concrete piles
    concrete piles

    concrete piles
    sheet piles

    grout piles
    Data

    Pile head elevation, as constructed * * * * *


    Pile cut-off elevation * * * * *
    Length of temporary casing - - * * -
    Length of permanent casing - - * * -
    Type, weight, drop and mechanical condition of hammer and
    * * * - -
    equivalent information for other equipment

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    Number and type of packings used and type and condition of
    * * * - -
    dolly used during driving of the pile

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    Set of pile or pile tube in millimetres per 10 blows or number of
    * * * - -
    blows per 25 mm of penetration

    If required, the sets taken at intervals during the last 3 m of


    ta * * * - -
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    driving

    If required, temporary compression of ground and pile from time


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    of a marked increase in driving resistance until pile reached its * * * - -


    final level
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    If required, driving resistance taken at regular intervals over the


    * * * - -
    last 3 m of driving
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    Soil samples taken and in-situ tests carried out during pile
    * * * * *
    installation
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    Length and details of reinforcements - - * * *


    Concrete mix - - * * *
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    Volume of concrete supplied to pile - - * * *


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    et

    All information regarding obstructions delays and other


    * * * * *
    interruptions to the work
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    1.3.3 Rejected materials

    1 Rejected materials are to be removed promptly from the Site.

    1.4 INSTALLATION TOLERANCES

    1.4.1 Setting Out

    1 Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at
    pile positions, as required by the Contract, shall be located by the Contractor from the main
    grid lines of the proposed structure. Before installation of the pile, the pile position relative to
    the main grid lines shall be verified.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 01: General Requirements for Piling Work

    1.4.2 Position

    1 For a pile cut off at or above ground level the maximum permitted deviation of the pile centre
    from the centre-point shown on the drawings shall be 75 mm in any direction. An additional
    tolerance for a pile head cut off below ground level will be permitted in accordance with
    Clauses 1.4.3 and 1.4.4.

    1.4.3 Verticality

    1 At the commencement of installation, the pile, or pile-forming equipment in the case of a


    driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall
    be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the
    finished pile from the vertical is 1 in 75.

    1.4.4 Rake

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    1 As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of

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    rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The
    piling rig shall be set and maintained to attain the required rake. The maximum permitted
    deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1
    in 15 for piles raking more than 1:6.
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    1.4.5 Tolerance Variations
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    1 In exceptional circumstances where these tolerances are difficult to achieve, the tolerances
    of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of
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    the implications of such action.


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    1.4.6 Forcible Corrections to Pile


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    1 Forcible corrections to concrete piles to overcome errors of position or alignment shall not be
    made. Forcible corrections may be made to other piles only if approved and where the pile
    shaft is not fully embedded in the soil.
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    1.5 NUISANCE AND DAMAGE


    et
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    1.5.1 Noise and Disturbance

    1 The Contractor shall carry out the work in such a manner and at such times as to minimise
    noise, vibration and other disturbance in order to comply with current environmental
    legislation.

    2 The Contractor shall endeavour to ascertain the nature and levels of noise produced by the
    mechanical equipment and plant that will be used. He shall than take steps to reduce either
    the level or the annoying characteristics, or both, of the noise. Reference should be made to
    BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment
    and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to
    piling operations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 01: General Requirements for Piling Work

    1.5.2 Damage to Adjacent Structures

    1 If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services
    or adjacent structures, he shall submit to the Engineer his proposals for making
    preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding
    such damage.

    1.5.3 Damage to Piles

    1 The Contractor shall ensure that during the course of the work, displacement or damage
    which would impair either performance or durability does not occur to completed piles.

    2 The Contractor shall submit to the Engineer his proposed sequence and timing for driving or
    boring piles, having the intent of avoiding damage to adjacent piles.

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    1.5.4 Temporary Support

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    1 The Contractor shall ensure that where required, any permanently free-standing piles are
    temporarily braced or stayed immediately after driving to prevent loosening of the piles in the
    ground and to ensure that the pile will not be damaged by oscillation, vibration or ground
    movement.
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    1.6 SAFETY
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    1.6.1 General
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    1 A competent person, properly qualified and experienced, should be appointed to supervise


    the piling operations. This person should be capable of recognising and assessing any
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    potential dangers as they arise; e.g., unexpected ground conditions that may require a
    change in construction technique, or unusual smells which may indicate the presence of
    ov

    noxious or dangerous gases.

    2 Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN
    o

    1997. Refer Section 1 for general safety standards to be adopted at a construction site.
    it
    et

    1.6.2 Life-Saving Appliances


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    1 The Contractor shall provide and maintain on the Site sufficient, proper and efficient life-
    saving appliances to the approval of the Engineer. The appliances must be conspicuous and
    available for use at all times.

    2 Site operatives shall be instructed in the use of safety equipment and periodic drills shall be
    held to ensure that all necessary procedures can be correctly observed.

    1.6.3 Driving

    1 Before any pile driving is started, the Contractor shall supply the Engineer with two copies of
    the code of signals to be employed, and shall have a copy of the code prominently displayed
    adjacent to the driving control station on the craft, structure or site from which the piles will be
    driven.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 02: Concrete Works for Piling

    2 CONCRETE WORKS FOR PILING ......................................................................... 2


    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.1.2 References 2
    2.2 MATERIALS ............................................................................................................ 2
    2.2.1 Cementitious 2
    2.2.2 Aggregate 2
    2.2.3 Water 2
    2.2.4 Admixtures 2
    2.2.5 Steel Reinforcement and Prestressing Steel 2
    2.3 CONCRETE MIXES FOR PILING WORK ............................................................... 3
    2.3.1 General 3

    .
    2.3.2 Grade Designation 3

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    2.3.3 Designed Mix 3

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    2.3.4 Durability 3
    2.3.5 Exposure Classes 3
    2.4
    2.4.1 General ta
    PLACING CONCRETE ............................................................................................ 3
    3
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    2.4.2 Inspection 4
    2.4.3 Cleanliness of Pile Bases 4
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    2.4.4 Workability of Concrete 4


    2.4.5 Compaction 4
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    2.4.6 Placing Concrete in Dry Borings 5


    2.4.7 Placing Concrete under Water or Drilling Fluid 5
    er
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    et
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    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 02: Concrete Works for Piling

    2 CONCRETE WORKS FOR PILING

    2.1 GENERAL

    2.1.1 Scope

    1 This part applies to cast in-situ as well as precast concrete work.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, General Requirements for Piling Work
    Part 3 Shallow Foundations
    Part 4 Deep Foundations

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    Part 5 Retaining Structures

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    Section 5 Concrete.

    2.1.2 References

    1 ta
    The following Standards are referred to in this Part:
    qa
    BS 8008......................Safety precautions and procedures for the construction and descent of
    machine-bored shafts for piling and other purposes
    as

    All Standards mentioned in Section 5


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    2.2 MATERIALS
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    2.2.1 Cementitious
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    1 All cementitious materials shall comply with the requirements of Section 5, Part 3.
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    2 All cementitious materials shall be stored in separate containers according to type in


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    waterproof stores or silos.


    et

    2.2.2 Aggregate
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    1 Aggregates shall comply with the requirements of Section 5, Part 2.

    2.2.3 Water

    1 If water for the Works is not available from a public supply, approval shall be obtained
    regarding the source of water. For quality of water refer to Section 5, Part 4.

    2.2.4 Admixtures

    1 Admixtures shall comply with the requirements of Section 5, Part 5

    2.2.5 Steel Reinforcement and Prestressing Steel

    1 Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free
    from loose rust and loose mill scale when installed in the Works. For requirements of steel
    reinforcement refer to Section 5, Part 11.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 02: Concrete Works for Piling

    2 The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in
    reinforcement shall be such that the full strength of each bar is effective across the joint and
    shall be made so that there is no detrimental displacement of the reinforcement during the
    construction of the pile.

    3 For requirements of prestressing steel refer to Section 5, Part 18.

    2.3 CONCRETE MIXES FOR PILING WORK

    2.3.1 General

    1 For general requirements of concrete mixes, trial mixes, batching, mixing and transportation
    of fresh concrete and testing of hardened concrete refer to Section 5.

    2.3.2 Grade Designation

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    1 Grades of concrete shall be as given in Section 5, Part 6.

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    2.3.3 Designed Mix

    1
    ta
    The Contractor shall be responsible for selecting the mix proportions to achieve the required
    qa
    strength and workability..

    2 Complete information on the mix and sources of aggregate for each grade of concrete and
    as

    the water/cementitious ratio and the proposed degree of workability shall be approved before
    work commences.
    se

    3 Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content


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    (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.
    ov

    4 The Contractor shall submit the slump value for approval before work commences.

    2.3.4 Durability
    it o

    1 For piles exposed to aggressive ground or groundwater, approved measures shall be taken
    et

    to ensure durability. Reference shall be made to Section 5, Part 6.


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    2.3.5 Exposure Classes

    1 The minimum cementitious content and type and the concrete grades shall be specified
    based on the exposure classes as given in Table 6.8, Section 5, Part 6.

    2.4 PLACING CONCRETE

    2.4.1 General

    1 The workability and method of placing and vibrating the concrete shall be such that a
    continuous monolithic concrete shaft of the full cross-section is formed.

    2 The concrete shall be placed without such interruption as would produce a cold joint in the
    pile. The method of placing shall be approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 02: Concrete Works for Piling

    3 The Contractor shall take all precautions in the design of the mix and placing of the concrete
    to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter
    which would adversely affect the performance of the pile shall be permitted to contaminate
    the concrete.

    2.4.2 Inspection

    1 Each pile bore which does not contain standing water or drilling fluid shall be inspected
    directly or indirectly before to concrete is placed in it. This inspection shall be carried out from
    the ground surface in the case of piles of less than 750 mm diameter. Torches or other
    approved means of lighting, measuring tapes, and a means of measuring verticality shall be
    provided. For piles of 750 mm diameter or larger, equipment shall be provided by the
    Contractor to enable his representatives and the Engineer to descend into the bore for the
    purpose of inspection. Any method of descent and the equipment used shall comply with the

    .
    requirements of BS 8008.

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    2.4.3 Cleanliness of Pile Bases

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    1 On completion of boring and where inspection of a dry pile bore indicates the necessity,

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    loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain
    water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the
    qa
    concrete shall be placed by tremie method. Large debris or accumulated sediment, or both
    of them, shall be removed using appropriate approved methods, which shall be designed to
    clean while at the same time minimising ground disturbance below the pile bases. Water or
    as

    drilling fluid shall be maintained at such levels throughout and following the cleaning
    operation that stability of the bore is preserved.
    se

    2.4.4 Workability of Concrete


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    1 Slump measured at the time of discharge into the pile bore shall be in accordance with the
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    standards shown in Table 2.1.


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    2.4.5 Compaction
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    et

    1 Internal vibrators may be used to compact concrete, with the approval of the Engineer
    obtained in advance for each specific use.
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    Table 2.1
    Standards for Concrete Slump
    Slump
    Piling mix
    Minimum Range Typical conditions of use
    workability
    mm mm
    Placed into water-free unlined or permanently lined bore
    of 600 mm diameter or over, or where concrete is placed
    A 75 75-150 below temporary casing, and where reinforcement is
    widely spaced leaving ample room for free movement of
    concrete between bars.
    Where reinforcement is not spaced widely, where
    B 100 100-200 concrete is placed within temporary casings, where pile
    bore is water-free, and the diameter less than 600 mm
    Where concrete is to be placed by tremie under water or
    C 150 150 or more drilling mud, or by pumping
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 02: Concrete Works for Piling

    2.4.6 Placing Concrete in Dry Borings

    1 Approved measures shall be taken to ensure that the structural strength of the concrete
    placed in all piles is not impaired through grout loss, segregation or bleeding.

    2 Concrete shall be placed by elephant trunk, and the free fall shall not exceed 1.2 m.

    2.4.7 Placing Concrete under Water or Drilling Fluid

    1 Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure
    that there is no accumulation of silt or other material at the base of the boring, and the
    Contractor shall ensure that heavily contaminated bentonite suspension, which could impair
    the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

    2 Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be

    l .
    discharged freely into the water or drilling fluid. Pumping of concrete may be approved where

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    appropriate.

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    3 A sample of the bentonite suspension shall be taken from the base of the boring using an
    approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing

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    of concrete shall not proceed. In this event the Contractor shall modify or replace the
    bentonite as approved to meet the specification.
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    4 The concrete shall be a rich, coherent mix and highly workable, and cement content shall be
    as

    in accordance with Clause 2.3.5.


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    5 The concrete shall be placed in such a manner that segregation does not occur.

    6 The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall
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    extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to
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    prevent direct contact between the first charge of concrete in the tremie and the water or
    drilling fluid. The pipe shall at all times penetrate the concrete which has previously been
    placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of
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    2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of
    it

    concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that
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    from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than
    m

    150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that
    external projections are minimised, allowing the tremie to pass within reinforcing cages
    without causing damage. The internal face of the pipe of the tremie shall be free from
    projections.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 03: Shallow Foundations

    3 SHALLOW FOUNDATIONS .................................................................................... 2


    3.1 GENERAL ............................................................................................................... 2
    3.1.1 Scope 2
    3.1.2 Definition 2
    3.1.3 References 2
    3.1.4 Limit States Considerations 2
    3.2 DESIGN CONSIDERATIONS .................................................................................. 3
    3.2.1 General 3
    3.2.2 Allowable Bearing Pressure 3
    3.2.3 Selection of Types of Shallow Foundation 3
    3.2.4 Pad foundations 4
    3.2.5 Strip foundations 4

    .
    3.2.6 Raft foundations 5

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    3.3 BASIS OF GEOTECHNICAL DESIGN .................................................................... 5

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    3.3.1 Design Requirements 5
    3.3.2 Design Situations 7
    3.3.3 Durability 8
    3.4 ta
    GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9
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    3.4.1 General 9
    3.4.2 Actions 10
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    3.4.3 Ground Properties 12


    3.4.4 Geometrical Data 13
    se

    3.4.5 Characteristic and Representative Values of Actions 13


    3.4.6 Characteristic Values of Geotechnical Parameters 13
    er

    3.4.7 Characteristic Values of Geometrical Data 14


    3.4.8 Geotechnical Design Report 14
    ov

    3.4.9 Actions and Design Situations 15


    3.4.10 Design and Construction Considerations 15
    o

    3.4.11 Foundations on Rock; Additional Design Considerations 16


    it
    et
    m
    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 03: Shallow Foundations

    3 SHALLOW FOUNDATIONS

    3.1 GENERAL

    3.1.1 Scope

    1 The provisions of this Section apply to shallow foundations including isolated, pads, strips and
    rafts.

    3.1.2 Definition

    1 Shallow foundations are taken to be those where the depth below finished ground level is
    less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is
    arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed

    . l
    as deep foundations.

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    rw
    3.1.3 References
    BS 8004,.....................Code of practice for foundations.

    ta
    BS EN 1990................Eurocode 0: Basis of Structural Design
    qa
    BS EN 1991................Eurocode 1: Actions on structures
    BS EN 1992................Eurocode 2: Design of concrete structures -
    BS EN 1993................Eurocode 3: Design of steel structures
    as

    BS EN 1994................Eurocode 4: Design of composite steel and concrete structures


    se

    BS EN 1995................Eurocode 5: Design of timber structures


    BS EN 1996................Eurocode 6: Design of masonry structures
    er

    BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules


    ov

    BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and


    testing
    BS EN 1998................Eurocode 8: Design of structures for earthquake resistance
    o

    BS 5930......................Code of Practice for Site Investigation


    it
    et

    3.1.4 Limit States Considerations


    m

    1 The following limit states shall be considered and an appropriate list shall be compiled:

    (a) Loss of overall stability;


    (b) Bearing resistance failure, punching failure, squeezing;
    (c) Failure by sliding;
    (d) Combined failure in the ground and in the structure;
    (e) Structural failure due to foundation movement;
    (f) Excessive settlements;
    (g) Excessive heave due to swelling, frost and other causes;
    (h) Unacceptable vibrations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 03: Shallow Foundations

    3.2 DESIGN CONSIDERATIONS

    3.2.1 General

    1 The depth to which foundations should be carried depends on two principal factors:

    (a) Reaching an adequate bearing stratum;


    (b) Penetration below the zone in which trouble may be expected from seasonal weather
    changes.

    2 Other factors such as ground movements, changes in groundwater conditions, long-term


    stability and heat transmitted from structures to the supporting ground may be important.

    3 Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose water-
    bearing sands and soils that change structure when loaded. Specialist advice should be

    l .
    sought where such conditions are indicated by ground investigation.

    .l.
    rw
    3.2.2 Allowable Bearing Pressure

    1 The center of area of a foundation or group of foundations should be arranged vertically

    ta
    under the centre of gravity of the imposed loading. If this is not possible, the effects on the
    qa
    structure of rotation and settlement of the foundation need to be considered.

    2 Where foundation support is provided by a number of separate bases these should, as far as
    as

    practicable, be proportioned so that differential settlement is minimal.


    se

    3.2.3 Selection of Types of Shallow Foundation


    er

    1 The selection of the appropriate type of shallow foundation will normally depend on the
    magnitude and disposition of the structural loads, the bearing capacity and settlement
    ov

    characteristics of the ground and the need to found in stable soil.

    2 A pad foundation is used for the purpose of distributing concentrated loads. Unless special
    o

    conditions control the design, relatively heavy column loads make it advantageous to use pad
    it

    foundations.
    et

    3 Strip foundations may be more appropriate where column loads are comparatively small and
    m

    closely spaced or where walls are heavy or heavily loaded.

    4 Adjacent pad foundations can be combined or joined together with ground beams to support
    eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns
    may be carried on ground beams spanning between the pad foundations.

    5 Where the allowable bearing pressure would result in large isolated foundations occupying
    the majority of the available area, it may be logical to join them to form a raft and spread the
    loads over the entire area. The combination of isolated foundations to form a raft sometimes
    results in a complex design and a large increase in the reinforcement requirement.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 03: Shallow Foundations

    6 In connection with the provision of foundations to an extension of an existing building,


    allowance should be made for differential movement of the foundations between the new and
    existing structure; such movement affects the structure above foundations. Where a degree
    of cracking and subsequent remedial work is not acceptable, provision for a joint between the
    extension and existing building should be considered. Where the foundations of an extension
    about the foundations of the existing building, the stability of the existing foundations should
    be ensured.

    3.2.4 Pad foundations

    1 For buildings such as low rise dwellings and lightly framed structures, pad foundations may
    be of unreinforced concrete provided that the angle of spread of load from the pier or base
    plate to the outer edge of the ground bearing does not exceed one (vertical) in one
    (horizontal) and that the stresses in the concrete due to bending and shear do not exceed
    tolerable limits. For buildings other than low rise and lightly framed structures, it is customary

    l .
    to use reinforced concrete foundations.

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    rw
    2 The thickness of the foundation should under no circumstances be less than 150 mm and will
    generally be greater than this to maintain cover to reinforcement where provided.

    3
    ta
    Where concrete foundations are used they should be designed in accordance with the design
    qa
    method appropriate to the loading assumptions.

    3.2.5 Strip foundations


    as

    1 Similar considerations to those for pad foundations apply to strip foundations. On sloping
    se

    sites strip foundations should be on a horizontal bearing, stepped where necessary to


    maintain adequate depth.
    er

    2 In continuous wall foundations it is recommended that reinforcement be provided wherever


    ov

    an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall
    foundations will normally be constructed in mass concrete provided that the angle of spread
    of load from the edge of the wall base to the outer edge of the ground bearing does not
    o

    exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where
    it

    regarding is likely to take place, may require to be designed as retaining walls to


    et

    accommodate steps between adjacent ground floor slabs or finished ground levels. At all
    m

    changes of level unreinforced foundations should be lapped at the steps for a distance at
    least equal to the thickness of the foundation or a minimum of 300mm. Where the height of
    the step exceeds the thickness of the foundation, special precautions should be taken. The
    thickness of reinforced strip foundations should be not less than 150mm, and care should be
    taken with the excavation levels to ensure that this minimum thickness is maintained. For the
    longitudinal spread of loads, sufficient reinforcement should be provided to withstand the
    tensions induced. It will sometimes be desirable to make strip foundations of inverted tee
    beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners
    and junctions the longitudinal reinforcement of each wall foundation should be lapped.

    3 Where the use of ordinary strip foundations would overstress the bearing strata, wide strip
    foundations designed to transmit the foundation loads across the full width of the strip may be
    used. The depth below the finished ground level should be the same as for ordinary strip
    foundations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 03: Shallow Foundations

    4 Where the nature of the ground is such that narrow trenches can be neatly cut down to the
    bearing stratum, an economical foundation may be achieved by filling the trenches with
    concrete. When deciding the trench width, account should be taken of normal building
    tolerances in relation to setting out dimensions. Where the thickness of such a foundation is
    500mm or more, any step should be not greater than the concrete thickness and the lap at
    such a step should be at least 1 m or twice the step height, whichever is the greater?

    5 Where fill or other loose materials occur above the bearing stratum adequate support is
    required to any excavation. Consideration may be given to the use of lean mix mass concrete
    replacement under ordinary strip footings placed at shallow depth. This mass concrete can
    be poured against either permanent or recoverable shuttering. This form of foundation
    provides a method of dealing with local areas where deeper foundations are required.

    3.2.6 Raft foundations

    l .
    1 General. Suitably designed raft foundations may be used in the following circumstances.

    .l.
    rw
    (a) For lightly loaded structures on soft natural ground where it is necessary to spread the
    load, or where there is variable support due to natural variations, made ground or
    weaker zones. In this case the function of the raft is to act as a bridge across the

    ta
    weaker zones. Rafts may form part of compensated foundations.
    qa
    (b) Where differential settlements are likely to be significant. The raft will require special
    design, involving an assessment of the disposition and distribution of loads, contact
    pressures and stiffness of the soil and raft.
    as

    3.3 BASIS OF GEOTECHNICAL DESIGN


    se

    3.3.1 Design Requirements


    er

    1 For each geotechnical design situation it shall be verified that no relevant limit state is
    ov

    exceeded.

    2 When defining the design situations and the limit states, the following factors should be
    o

    considered:
    it
    et

    (a) Site conditions with respect to overall stability and ground movements;
    m

    (b) Nature and size of the structure and its elements, including any special requirements
    such as the design life;
    (c) Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities,
    vegetation, hazardous chemicals);
    (d) Ground conditions;
    (e) Ground-water conditions;
    (f) Regional seismicity;
    (g) Influence of the environment (hydrology, surface water, subsidence, seasonal changes
    of temperature and moisture).

    3 Limit states can occur either in the ground or in the structure or by combined failure in the
    structure and the ground.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 03: Shallow Foundations

    4 Limit states should be verified by any appropriate method such as calculation method as
    described in 3.4;

    5 In practice, experience will often show which type of limit state will govern the design and the
    avoidance of other limit states may be verified by a control check.

    6 Buildings should normally be protected against the penetration of ground-water or the


    transmission of vapor or gases to their interiors.

    7 If practicable, the design results should be checked against comparable experience.

    8 In order to establish minimum requirements for the extent and content of geotechnical
    investigations, calculations and construction control checks, the complexity of each
    geotechnical design shall be identified together with the associated risks. In particular, a
    distinction shall be made between:

    l .
    .l.
    (a) L ight and simple structures and small earthworks for which it is possible to ensure that
    the minimum requirements will be satisfied by experience and qualitative geotechnical

    rw
    investigations, with negligible risk;
    (b) Other geotechnical structures.

    9 ta
    For structures and earthworks of low geotechnical complexity and risk, such as defined
    qa
    above, simplified design procedures may be applied.
    as

    10 To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3,


    may be introduced.
    se

    11 A preliminary classification of a structure according to Geotechnical Category should


    normally be performed prior to the geotechnical investigations. The category should be
    er

    checked and changed, if necessary, at each stage of the design and construction process.
    ov

    12 The procedures of higher categories may be used to justify more economic designs, or if the
    designer considers them to be appropriate.
    it o

    13 The various design aspects of a project can require treatment in different Geotechnical
    et

    Categories. It is not required to treat the whole of the project according to the highest of these
    categories.
    m

    14 Geotechnical Category 1 should only include small and relatively simple structures:

    (a) For which it is possible to ensure that the fundamental requirements will be satisfied on
    the basis of experience and qualitative geotechnical investigations;
    (b) With negligible risk.

    15 Geotechnical Category 1 procedures should be used only where there is negligible risk in
    terms of overall stability or ground movements and in ground conditions, which are known
    from comparable local experience to be sufficiently straightforward. In these cases the
    procedures may consist of routine methods for foundation design and construction.

    16 Geotechnical Category 1 procedures should be used only if there is no excavation below the
    water table or if comparable local experience indicates that a proposed excavation below the
    water table will be straightforward.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 03: Shallow Foundations

    17 Geotechnical Category 2 should include conventional types of structure and foundation with
    no exceptional risk or difficult soil or loading conditions

    18 Designs for structures in Geotechnical Category 2 should normally include quantitative


    geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

    19 Routine procedures for field and laboratory testing and for design and execution may be used
    for Geotechnical Category 2 designs.

    (a) the following are examples of conventional structures or parts of structures complying
    with Geotechnical Category 2:
    (i) Shallow foundations;
    (ii) Pile foundations;

    .
    (iii) Walls and other structures retaining or supporting soil or water;

    l
    .l.
    (iv) Excavations;

    rw
    (v) Bridge piers and abutments;
    (vi) Embankments and earthworks;
    (vii)
    ta
    Ground anchors and other tie-back systems;
    qa
    (viii) Tunnels in hard, non-fractured rock and not subjected to special water tightness
    or other requirements.
    as

    20 Geotechnical Category 3 should include structures or parts of structures, which fall outside
    the limits of Geotechnical Categories 1 and 2.
    se

    21 Geotechnical Category 3 should normally include alternative provisions and rules to those in
    er

    this standard.
    ov

    (a) Geotechnical Category 3 includes the following examples:


    (i) Very large or unusual structures;
    o

    (ii) Structures involving abnormal risks, or unusual or exceptionally difficult ground


    it

    or loading conditions;
    et

    (iii) Structures in highly seismic areas;


    m

    (iv) Structures in areas of probable site instability or persistent ground movements


    that require separate investigation or special measures.

    3.3.2 Design Situations

    1 Both short-term and long-term design situations shall be considered.

    2 In geotechnical design, the detailed specifications of design situations should include, as


    appropriate:

    (a) The actions, their combinations and load cases;


    (b) The general suitability of the ground on which the structure is located with respect to
    overall stability and ground movements;
    (c) The disposition and classification of the various zones of soil, rock and elements of
    construction, which are involved in any calculation model;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 8
    Part 03: Shallow Foundations

    (d) Dipping bedding planes;


    (e) Mine workings, caves or other underground structures;
    (f) In the case of structures resting on or near rock:
    (i) inter bedded hard and soft strata;
    (ii) faults, joints and fissures;
    (iii) possible instability of rock blocks;
    (iv) solution cavities, such as swallow holes or fissures filled with soft material, and
    continuing solution processes;
    (g) The environment within which the design is set, including the following:
    (i) effects of scour, erosion and excavation, leading to changes in the geometry of
    the ground surface;

    l .
    .l.
    (ii) effects of chemical corrosion;

    rw
    (iii) effects of weathering;
    (iv) effects of long duration droughts;
    (v)
    ta
    variations in ground-water levels, including, e.g. the effects of dewatering,
    possible flooding, failure of drainage systems, water exploitation;
    qa
    (vi) the presence of gases emerging from the ground;
    as

    (h) Earthquakes;
    (i) Ground movements caused by subsidence due to mining or other activities;
    se

    (j) The sensitivity of the structure to deformations;


    er

    (k) The effect of the new structure on existing structures, services and the local
    environment.
    ov

    3.3.3 Durability
    o

    1 At the geotechnical design stage, the significance of environmental conditions shall be


    it

    assessed in relation to durability and to enable provisions to be made for the protection or
    et

    adequate resistance of the materials.


    m

    2 In designing for durability of materials used in the ground, the following should be considered:

    (a) For concrete:


    (i) Aggressive agents in the ground-water or in the ground or fill material, such as
    acids or sulfate salts;
    (b) For steel:
    (i) Chemical attack where foundation elements are buried in ground that is
    sufficiently permeable to allow the percolation of ground-water and oxygen;
    (ii) Corrosion on the faces of sheet pile walls exposed to free water, particularly in
    the mean water level zone;
    (iii) The pitting type of corrosive attack on steel embedded in fissured or porous
    concrete, particularly for rolled steel where the mill scale, acting as a cathode,
    promotes electrolytic action with the scale-free surface acting as an anode;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 9
    Part 03: Shallow Foundations

    (c) For timber:


    (i) Fungi and aerobic bacteria in the presence of oxygen;
    (d) For synthetic fabrics:
    (i) The ageing effects of UV exposure or ozone degradation or the combined
    effects of temperature and stress, and secondary effects due to chemical
    degradation.

    3 Reference should be made to durability provisions in construction materials standards.

    3.4 GEOTECHNICAL DESIGN BY CALCULATION

    3.4.1 General

    .
    1 Design by calculation shall be in accordance with the fundamental requirements of EN 1990

    l
    .l.
    and with the particular rules of this specification. Design by calculation involves:

    rw
    (a) Actions, which may be either imposed loads or imposed displacements, e.g. from
    ground movements;
    (b) Properties of soils, rocks and other materials;ta
    qa
    (c) Geometrical data;
    (d) Limiting values of deformations, crack widths, vibrations etc;
    as

    (e) Calculation models.


    se

    2 It should be considered that knowledge of the ground conditions depends on the extent and
    quality of the geotechnical investigations. Such knowledge and the control of workmanship
    er

    are usually more significant to fulfilling the fundamental requirements than is precision in the
    ov

    calculation models and partial factors.

    3 The calculation model shall describe the assumed behavior of the ground for the limit state
    o

    under consideration.
    it
    et

    4 If no reliable calculation model is available for a specific limit state, analysis of another limit
    state shall be carried out using factors to ensure that exceeding the specific limit state
    m

    considered is sufficiently improbable. Alternatively, design by prescriptive measures,


    experimental models and load tests, or the observational method, shall be performed.

    5 The calculation model may consist of any of the following:

    (a) An analytical model;


    (b) A semi-empirical model;
    (c) A numerical model.

    6 Any calculation model shall be either accurate or err on the side of safety.

    7 A calculation model may include simplifications.

    8 If needed, a modification of the results from the model may be used to ensure that the design
    calculation is either accurate or errs on the side of safety.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 10
    Part 03: Shallow Foundations

    9 If the modification of the results makes use of a model factor, it should take account of the
    following:

    (a) The range of uncertainty in the results of the method of analysis;


    (b) Any systematic errors known to be associated with the method of analysis.

    10 If an empirical relationship is used in the analysis, it shall be clearly established that it is


    relevant for the prevailing ground conditions.

    11 Limit states involving the formation of a mechanism in the ground should be readily checked
    using a calculation model. For limit states defined by deformation considerations, the
    deformations should be evaluated by calculation or otherwise assessed.

    NOTE: many calculation models are based on the assumption of a sufficiently ductile
    performance of the ground/structure system. A lack of ductility, however, will lead to an

    .
    ultimate limit state characterized by sudden collapse.

    l
    .l.
    12 Numerical methods can be appropriate if compatibility of strains or the interaction between

    rw
    the structure and the soil at a limit state are considered.

    13 Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for

    ta
    the relative stiffness of structure and ground, may be needed in cases where a combined
    qa
    failure of structural members and the ground could occur. Examples include raft foundations,
    laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain
    compatibility for materials that are brittle or that have strain-softening properties.
    as

    14 In some problems, such as excavations supported by anchored or strutted flexible walls, the
    se

    magnitude and distribution of earth pressures, internal structural forces and bending
    moments depend to a great extent on the stiffness of the structure, the stiffness and strength
    er

    of the ground and the state of stress in the ground.


    ov

    15 In these problems of ground-structure interaction, analyses should use stress-strain


    relationships for ground and structural materials and stress states in the ground that are
    sufficiently representative, for the limit state considered, to give a safe result.
    it o

    3.4.2 Actions
    et

    1 The definition of actions shall be taken as:


    m

    (a) Set of forces (loads) applied to the structure (direct action);


    (b) Set of imposed deformations or accelerations caused for example, by temperature
    changes, moisture variation, uneven settlement or earthquakes (indirect action).
    The values of actions shall be taken from EN 1991 or equivalent international standard,
    where relevant.

    2 The values of geotechnical actions to be used shall be selected, since they are known before
    a calculation is performed; they may change during that calculation.

    NOTE: Values of geotechnical actions may change during the course of calculation. In such
    cases they will be introduced as a first estimate to start the calculation with a preliminary,
    known value.

    3 Any interaction between the structure and the ground shall be taken into account when
    determining the actions to be adopted in the design.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 11
    Part 03: Shallow Foundations

    4 In geotechnical design, the following should be considered for inclusion as actions:

    (a) the weight of soil, rock and water;


    (b) stresses in the ground;
    (c) earth pressures and ground-water pressure;
    (d) free water pressures, including wave pressures;
    (e) ground-water pressures;
    (f) seepage forces;
    (g) dead and imposed loads from structures;
    (h) surcharges;
    (i) mooring forces;

    l .
    (j) removal of load or excavation of ground;

    .l.
    (k) traffic loads;

    rw
    (l) movements caused by mining or other caving or tunneling activities;
    (m)
    ta
    swelling and shrinkage caused by vegetation, climate or moisture changes;
    qa
    (n) movements due to creeping or sliding or settling ground masses;
    (o) movements due to degradation, dispersion, decomposition, self-compaction and
    solution;
    as

    (p) movements and accelerations caused by earthquakes, explosions, vibrations and


    se

    dynamic loads;
    (q) temperature effects, including frost action;
    er

    (r) imposed pre-stress in ground anchors or struts;


    ov

    (s) down drag.

    5 Consideration shall be given to the possibility of variable actions occurring both jointly and
    o

    separately.
    it
    et

    6 The duration of actions shall be considered with reference to time effects in the material
    m

    properties of the soil, especially the drainage properties and compressibility of fine-grained
    soils.

    7 Actions, which are applied repeatedly, and actions with variable intensity shall be identified
    for special consideration with regard to, e.g. continuing movements, liquefaction of soils,
    change of ground stiffness and strength.

    8 Actions that produce a dynamic response in the structure and the ground shall be identified
    for special consideration.

    9 Actions in which ground- and free-water forces predominate shall be identified for special
    consideration with regard to deformations, fissuring, variable permeability and erosion.

    NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in
    some situations be considered as coming from a single source. If they are considered so, a
    single partial factor may be applied to the sum of these actions or to the sum of their effects.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 12
    Part 03: Shallow Foundations

    3.4.3 Ground Properties

    1 Properties of soil and rock masses, as quantified for design calculations by geotechnical
    parameters, shall be obtained from test results, either directly or through correlation, theory
    or empiricism, and from other relevant data.

    2 Values obtained from test results and other data shall be interpreted appropriately for the limit
    state considered.

    3 Account shall be taken of the possible differences between the ground properties and
    geotechnical parameters obtained from test results and those governing the behavior of the
    geotechnical structure.

    4 The above differences can be due to the following factors:

    .
    (a) many geotechnical parameters are not true constants but depend on stress level and

    l
    .l.
    mode of deformation;

    rw
    (b) soil and rock structure (e.g. fissures, laminations, or large particles) that may play a
    different role in the test and in the geotechnical structure;
    (c) time effects;
    ta
    qa
    (d) the softening effect of percolating water on soil or rock strength;
    (e) the softening effect of dynamic actions;
    as

    (f) the brittleness or ductility of the soil and rock tested;


    (g) the method of installation of the geotechnical structure;
    se

    (h) the influence of workmanship on artificially placed or improved ground;


    er

    (i) the effect of construction activities on the properties of the ground.


    ov

    5 When establishing values of geotechnical parameters, the following should be considered:

    (a) published and well recognized information relevant to the use of each type of test in
    o

    the appropriate ground conditions;


    it
    et

    (b) the value of each geotechnical parameter compared with relevant published data and
    local and general experience;
    m

    (c) the variation of the geotechnical parameters that are relevant to the design;
    (d) the results of any large scale field trials and measurements from neighboring
    constructions;
    (e) any correlations between the results from more than one type of test;
    (f) any significant deterioration in ground material properties that may occur during the
    lifetime of the structure.

    6 Calibration factors shall be applied where necessary to convert laboratory or field test results
    according to EN 1997-2 into values that represent the behavior of the soil and rock in the
    ground, for the actual limit state, or to take account of correlations used to obtain derived
    values from the test results.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 13
    Part 03: Shallow Foundations

    3.4.4 Geometrical Data

    1 The level and slope of the ground surface, water levels, levels of interfaces between strata,
    excavation levels and the dimensions of the geotechnical structure shall be treated as
    geometrical data.

    3.4.5 Characteristic and Representative Values of Actions

    1 Characteristic and representative values of actions shall be derived in accordance with EN


    1990:2002 and the various parts of EN 1991.

    3.4.6 Characteristic Values of Geotechnical Parameters

    1 The selection of characteristic values for geotechnical parameters shall be based on results
    and derived values from laboratory and field tests, complemented by well-established

    l .
    experience.

    .l.
    rw
    2 The characteristic value of a geotechnical parameter shall be selected as a cautious estimate
    of the value affecting the occurrence of the limit state.

    3
    ta
    The selection of characteristic values for geotechnical parameters shall take account of the
    following:
    qa
    (a) geological and other background information, such as data from previous projects;
    as

    (b) the variability of the measured property values and other relevant information, e.g.
    from existing knowledge;
    se

    (c) the extent of the field and laboratory investigation;


    er

    (d) the type and number of samples;


    (e) the extent of the zone of ground governing the behavior of the geotechnical structure
    ov

    at the limit state being considered;


    (f) the ability of the geotechnical structure to transfer loads from weak to strong zones in
    o

    the ground.
    it
    et

    4 Characteristic values can be lower values, which are less than the most probable values, or
    upper values, which are greater.
    m

    5 For each calculation, the most unfavorable combination of lower and upper values of
    independent parameters shall be used.

    6 The zone of ground governing the behavior of a geotechnical structure at a limit state is
    usually much larger than a test sample or the zone of ground affected in an in situ test.
    Consequently the value of the governing parameter is often the mean of a range of values
    covering a large surface or volume of the ground. The characteristic value should be a
    cautious estimate of this mean value.

    7 If the behavior of the geotechnical structure at the limit state considered is governed by the
    lowest or highest value of the ground property, the characteristic value should be a cautious
    estimate of the lowest or highest value occurring in the zone governing the behavior.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 14
    Part 03: Shallow Foundations

    8 When selecting the zone of ground governing the behavior of a geotechnical structure at a
    limit state, it should be considered that this limit state may depend on the behavior of the
    supported structure. For instance, when considering a bearing resistance ultimate limit state
    for a building resting on several footings, the governing parameter should be the mean
    strength over each individual zone of ground under a footing, if the building is unable to resist
    a local failure. If, however, the building is stiff and strong enough, the governing parameter
    should be the mean of these mean values over the entire zone or part of the zone of ground
    under the building.

    9 If statistical methods are employed in the selection of characteristic values for ground
    properties, such methods should differentiate between local and regional sampling and
    should allow the use of a prior knowledge of comparable ground properties.

    10 If statistical methods are used, the characteristic value should be derived such that the
    calculated probability of a worse value governing the occurrence of the limit state under

    l .
    consideration is not greater than 5%.

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    NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean
    value of the limited set of geotechnical parameter values, with a confidence level of 95%;
    where local failure is concerned, a cautious estimate of the low value is a 5% fractal.

    11
    ta
    When using standard tables of characteristic values related to soil investigation parameters,
    qa
    the characteristic value shall be selected as a very cautious value.

    3.4.7 Characteristic Values of Geometrical Data


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    1 Characteristic values of the levels of ground and ground-water or free water shall be
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    measured, nominal or estimated upper or lower levels.


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    2 Characteristic values of levels of ground and dimensions of geotechnical structures or


    elements should usually be nominal values.
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    3.4.8 Geotechnical Design Report


    o

    1 The assumptions, data, methods of calculation and results of the verification of safety and
    it

    serviceability shall be recorded in the Geotechnical Design Report.


    et

    2 The level of detail of the Geotechnical Design Reports will vary greatly, depending on the
    m

    type of design. For simple designs, a single sheet may be sufficient.

    3 The Geotechnical Design Report should normally include the following items, with cross-
    reference to the Ground Investigation Report :

    (a) a description of the site and surroundings;


    (b) a description of the ground conditions;
    (c) a description of the proposed construction, including actions;
    (d) design values of soil and rock properties, including justification, as appropriate;
    (e) statements on the codes and standards applied;
    (f) statements on the suitability of the site with respect to the proposed construction and
    the level of acceptable risks;
    (g) geotechnical design calculations and drawings;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 15
    Part 03: Shallow Foundations

    (h) foundation design recommendations;


    (i) a note of items to be checked during construction or requiring maintenance or
    monitoring.

    4 The Geotechnical Design Report shall include a plan of supervision and monitoring, as
    appropriate. Items, which require checking during construction or, which require maintenance
    after construction shall be clearly identified. When the required checks have been carried out
    during construction, they shall be recorded in an addendum to the Report.

    5 In relation to supervision and monitoring the Geotechnical Design Report should state:

    (a) the purpose of each set of observations or measurements;


    (b) the parts of the structure, which are to be monitored and the locations at which
    observations are to be made;

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    (c) the frequency with which readings is to be taken;

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    (d) the ways in which the results are to be evaluated;

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    (e) the range of values within which the results are to be expected;
    (f)
    (g) ta
    the period of time for which monitoring is to continue after construction is complete;
    the parties responsible for making measurements and observations, for interpreting
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    the results obtained and for maintaining the instruments.

    6 An extract from the Geotechnical Design Report, containing the supervision, monitoring and
    as

    maintenance requirements for the completed structure, shall be provided to the owner/client.
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    3.4.9 Actions and Design Situations


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    1 Design situations shall be selected in accordance with 3.3.2.


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    2 The actions listed in 3.4.2(4) should be considered when selecting the limit states for
    calculation.
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    3 If structural stiffness is significant, an analysis of the interaction between the structure and
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    the ground should be performed in order to determine the distribution of actions.


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    3.4.10 Design and Construction Considerations

    1 When choosing the depth of a shallow foundation the following shall be considered:

    (a) reaching an adequate bearing stratum;


    (b) the depth above which shrinkage and swelling of clay soils, due to seasonal weather
    changes, or to trees and shrubs, may cause appreciable movements;
    (c) the level of the water table in the ground and the problems, which may occur if
    excavation for the foundation is required below this level;
    (d) possible ground movements and reductions in the strength of the bearing stratum by
    seepage or climatic effects or by construction procedures;
    (e) the effects of excavations on nearby foundations and structures;
    (f) anticipated excavations for services close to the foundation;
    (g) high or low temperatures transmitted from the building;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 16
    Part 03: Shallow Foundations

    (h) the possibility of scour;


    (i) the effects of variation of water content due to long periods of drought, and subsequent
    periods of rain, on the properties of volume-unstable soils in arid climatic areas;
    (j) the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

    2 In addition to fulfilling the performance requirements, the design foundation width shall take
    account of practical considerations such as economic excavation, setting out tolerances,
    working space requirements and the dimensions of the wall or column supported by the
    foundation.

    3 One of the following design methods shall be used for shallow foundations:

    (a) a direct method, in which separate analyses are carried out for each limit state. When
    checking against an ultimate limit state, the calculation shall model as closely as

    .
    possible the failure mechanism, which is envisaged. When checking against a

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    serviceability limit state, a settlement calculation shall be used;

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    (b) an indirect method using comparable experience and the results of field or laboratory
    measurements or observations, and chosen in relation to serviceability limit state loads
    so as to satisfy the requirements of all relevant limit states;
    (c) ta
    a prescriptive method in which a presumed bearing resistance is used.
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    3.4.11 Foundations on Rock; Additional Design Considerations
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    1 The design of shallow foundations on rock shall take account of the following features:
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    (a) the deformability and strength of the rock mass and the permissible settlement of the
    supported structure;
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    (b) the presence of any weak layers, for example solution features or fault zones, beneath
    the foundation;
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    (c) the presence of bedding joints and other discontinuities and their characteristics (for
    example filling, continuity, width, spacing);
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    (d) the state of weathering, decomposition and fracturing of the rock;


    et

    (e) disturbance of the natural state of the rock caused by construction activities, such as,
    for example, underground works or slope excavation, being near to the foundation.
    m

    2 Shallow foundations on rock may normally be designed using the method of presumed
    bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and
    sandstones, the presumed bearing pressure are limited by the compressive strength of the
    concrete foundation.

    3 The settlement of a foundation may be assessed on the basis of comparable experience


    related to rock mass classification.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 04: Deep Foundations

    4 DEEP FOUNDATIONS ............................................................................................ 4


    4.1 PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4
    4.1.1 General 4
    4.1.2 Limit States Considerations 4
    4.1.3 Precast Reinforced and Prestressed Concrete Piles 4
    4.1.4 Materials and components 5
    4.1.5 Prestressing 7
    4.1.6 Driving Piles 8
    4.1.7 Risen Piles 10
    4.1.8 Repair and lengthening of piles 10
    4.1.9 Cutting off pile heads 10
    4.2 PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10

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    4.2.1 Scope 10
    4.2.2 References 11

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    4.2.3 Submittals 11
    4.2.4 Quality Assurance 11
    4.2.5
    4.2.6
    Tolerances in Pile Dimensions
    Handling, Transportation, Storage and Acceptance of Piles ta 11
    12
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    4.2.7 Materials and components 12
    4.2.8 Driving piles 13
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    4.2.9 Risen Piles 14


    4.2.10 Repair and lengthening of piles 15
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    4.2.11 Cutting off pile heads 15


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    4.3 BORED CAST IN PLACE PILES ........................................................................... 15


    4.3.1 Scope 15
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    4.3.2 References 16
    4.3.3 Quality Assurance 16
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    4.3.4 Materials 16
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    4.3.5 Boring 17
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    4.3.6 Extraction of casing 19


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    4.4 BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND


    CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21
    4.4.1 Scope 21
    4.4.2 Materials 21
    4.4.3 Boring 22
    4.4.4 Placing of concrete or grout 23
    4.4.5 Cutting off pile heads 23
    4.5 DRIVEN CAST IN PLACES PILES ........................................................................ 23
    4.5.1 Scope 23
    4.5.2 Submittals 24
    4.5.3 Quality Assurance 24
    4.5.4 Materials 24
    4.5.5 Driving piles 25
    4.5.6 Risen Piles 26
    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 04: Deep Foundations

    4.5.7 Extraction of casing 26


    4.6 STEEL PILES ........................................................................................................ 28
    4.6.1 Scope 28
    4.6.2 References 28
    4.6.3 Submittals 28
    4.6.4 Quality Assurance 28
    4.6.5 Delivery, Storage and Handling 29
    4.6.6 Materials 29
    4.6.7 Acceptance Standards For Welds 30
    4.6.8 Acceptability and inspection of coatings 31
    4.6.9 Driving of piles 31
    4.6.10 Risen Piles 33
    4.6.11 Preparation of pile heads 33

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    4.7 MICROPILES (TO BE ADDED LATER) ................................................................. 33
    4.8 REDUCTION OF FRICTION ON PILES ................................................................ 33

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    4.8.1 Scope 33
    4.8.2 Submittals 33
    4.8.3 Friction Reducing Methods
    ta 33
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    4.8.4 Inspection 34
    4.8.5 Driving resistance 35
    4.9 PILE LOAD TESTING ........................................................................................... 35
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    4.9.1 Static Load Testing of Piles 35


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    4.9.2 Presentation of results 45


    4.9.3 Low strain Integrity test 47
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    4.9.4 Grosshole Sonic Logging Test 48


    4.9.5 Calliper Logging Test 48
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    4.9.6 Axial Tensile Load Test 48


    4.9.7 Lateral Load Test 48
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    4.9.8 Alternative Methods for Testing Piles 48


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    4.10 DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51


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    4.10.1 Design method 51


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    4.10.2 Verification of Resistance for Structural and Ground Limit States in Persistent and
    Transient Situations 51
    4.10.3 Design Considerations 51
    4.11 AXIALLY LOADED PILES ..................................................................................... 52
    4.11.1 Limit state design 52
    4.11.2 Compressive Ground Resistance 53
    4.11.3 Ultimate compressive resistance from static load tests 54
    4.11.4 Ultimate compressive resistance from ground test results 55
    4.11.5 Ultimate compressive resistance from dynamic impact tests 56
    4.11.6 Ultimate compressive resistance by applying pile driving formulae 56
    4.11.7 Ultimate compressive resistance from wave equation analysis 56
    4.11.8 Ground tensile resistance 57
    4.11.9 Ultimate tensile resistance from pile load tests 57
    4.11.10 Ultimate tensile resistance from ground test results 57
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 04: Deep Foundations

    4.11.11 Vertical displacements of pile foundations 58


    4.11.12 Pile foundations in compression 58
    4.11.13 Pile foundations in tension 58
    4.12 TRANSVERSELY LOADED PILES ....................................................................... 58
    4.12.1 Design method 58
    4.12.2 Transverse load resistance from pile load tests 59
    4.12.3 Transverse load resistance from ground test results and pile strength parameters 59
    4.12.4 Transverse displacement 60

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    ta
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    se
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    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 04: Deep Foundations

    4 DEEP FOUNDATIONS

    4.1 PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

    4.1.1 General

    1 The provisions of this Part apply to end-bearing piles, friction piles, tension piles and
    transversely loaded piles installed by driving, by jacking, and by screwing or boring with or
    without grouting.

    4.1.2 Limit States Considerations

    1 The following limit states shall be considered and an appropriate list shall be compiled:

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    (a) Loss of overall stability;

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    (b) bearing resistance failure of the pile foundation;

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    (c) Uplift or insufficient tensile resistance of the pile foundation;
    (d) Failure in the ground due to transverse loading of the pile foundation;
    (e)
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    Structural failure of the pile in compression, tension, bending, buckling or shear;
    qa
    (f) combined failure in the ground and in the pile foundation;
    (g) combined failure in the ground and in the structure;
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    (h) Excessive settlement;


    (i) Excessive heave;
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    (j) Excessive lateral movement;


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    (k) Unacceptable vibrations.


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    4.1.3 Precast Reinforced and Prestressed Concrete Piles

    1 Scope
    it o

    (a) This Part applies to precast concrete driven piles usually supplied for use in a single
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    length without facility for joining lengths together.


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    (b) Related Sections and Parts are as follows:

    2 References

    (a) The following Standards are referred to in this Part:


    BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates
    BS 3100,.....................Steel castings for general engineering purposes
    BS 2789,.....................Spheroidal graphite or nodular graphite cast iron
    BS 8110,.....................Structural use of concrete.

    3 Submittals

    (a) The Contractor shall order the piles to suit the construction programme and seek the
    Engineer's approval before placing the order. When preliminary piles are specified,
    the approval of the piles for the main work will not necessarily be given until the results
    of the driving and loading tests on preliminary piles have been received and evaluated.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 04: Deep Foundations

    4 Quality Assurance

    (a) After a pile has been cast, the date of casting, reference number, length and, where
    appropriate, the prestressing force shall be clearly inscribed on the top surface of the
    pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall
    be marked at the proper locations on each pile.

    5 Tolerances in Pile Dimensions

    (a) The cross-sectional dimensions of the pile shall be not less than those specified and
    shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by
    more than 6 mm from any straight line 3 m long joining two points on that face, nor
    shall the centre of area of the pile at any cross section along its length deviate by more
    than 1/500 of the pile length from a line joining the centres of area at the ends of the

    .
    pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

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    be reduced below 6 mm on a pro rata basis in accordance with actual length.

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    6 Handling, Transportation and Storage of Piles

    (a) The method and sequence of lifting, handling, and storage of piles transporting and

    ta
    storing piles shall be such as to avoid shock loading and to ensure that the piles are
    qa
    not damaged. Only the designated lifting and support points shall be used. During
    transport and storage, piles shall be appropriately supported under the marked lifting
    points or fully supported along their length.
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    (b) All piles within a stack shall be in groups of the same length. Packing of uniform
    thickness shall be provided between piles at the lifting points.
    se

    (c) Concrete shall at no time be subjected to loading, including its own weight, which will
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    induce a compressive stress in it exceeding 0.33 of its strength at the time of loading
    or of the specified strength, whichever is the lesser. For this purpose the assessment
    ov

    of the strength of the concrete and of the stresses produced by the loads shall be
    subject to the agreement of the Engineer.
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    (d) Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The
    it

    measurement shall be made with the pile in its working attitude.


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    4.1.4 Materials and components


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    1 Fabricated Steel Components

    (a) In the manufacture of precast concrete piles, fabricated steel components shall comply
    with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and
    ductile iron components with BS 2789.

    2 Pile Toes

    (a) Pile toes shall be constructed so as to ensure that damage is not caused to the pile
    during installation. Where positional fixity is required on an inclined rock surface or in
    other circumstances, an approved shoe may be required.

    3 Pile Head Reinforcement

    (a) The head of each pile shall be so reinforced or banded as to prevent bursting of the
    pile under driving conditions.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 04: Deep Foundations

    4 Main Reinforcement

    (a) The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in
    one continuous length unless otherwise specified. In piles more than 12 m long, lap
    splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no
    more than 25 % of the bars lapped at one location, and laps staggered by a minimum
    of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is
    effective across the joint.
    (b) Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.
    (c) Sufficient reinforcement shall be provided for lifting and handling purposes.

    5 Concrete

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    (a) Unless otherwise agreed by the Engineer, concrete shall be compacted with the

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    assistance of vibrators. Internal vibrators shall be capable of producing not less than

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    150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not
    closer than 75 mm to shuttering.

    (b)
    ta
    Vibrators shall be operated in such a manner that neither segregation of the concrete
    mix constituents nor displacement of reinforcement occurs.
    qa
    (c) Immediately after compaction, concrete shall he adequately protected from the harmful
    effects of the weather, including wind, rain, rapid temperature changes and frost. It
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    shall be protected from drying out by an approved method of curing.


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    (d) Piles shall not be removed from formwork until a sufficient pile concrete strength has
    been achieved to allow the pile to be handled without damage.
    er

    (e) The period of curing at an ambient temperature of 10 C shall not be less than that
    ov

    shown in Table 4.1. If the temperature is greater or less than 10 C, the periods given
    shall be adjusted accordingly and shall be approved.
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    (f) When steam or accelerated curing is used the curing procedure shall be approved.
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    Four hours must elapse from the completion of placing concrete before the
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    temperature is raised. The rise in temperature within any period of 30 min shall not
    exceed 10 C and the maximum temperature attained shall not exceed 70 C. The rate
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    of subsequent cooling shall not exceed the rate of heating.

    Table 4.1
    Period of Curing at 10 C
    Wet curing time after
    Type of cement
    completion of placing concrete, d

    Ordinary Portland 4
    Sulphate-resisting Portland 4
    Portland blast-furnace 4
    Super-sulphated 4
    Rapid-hardening Portland 3
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 04: Deep Foundations

    6 Formwork

    (a) shaped point or shoe, then the end of the pile shall be symmetrical about the
    longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile,
    shall be lined with steel tubes; alternatively, approved inserts may be cast in.
    (b) Formwork shall be robust, clean and so constructed as to prevent loss of grout or
    aggregate from the wet concrete and ensure the production of uniform pile sections,
    free from defects. The piles are to be removed from the formwork carefully so as to
    prevent damage.

    4.1.5 Prestressing

    1 General

    (a) Tensioning shall be carried out only when the Engineer is present, unless otherwise

    .
    approved. In cases where piles are manufactured off site, the Contractor shall ensure

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    that the Engineer is given adequate notice and every facility for inspecting the
    manufacturing process.

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    (b) Prestressing operations shall be carried out only under the direction of an experienced
    and competent supervisor. All personnel operating the stressing equipment shall have

    (c)
    been trained in its use.
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    The calculated extensions and total forces, including allowance for losses, shall be
    qa
    agreed with the Engineer before stressing is commenced.
    (d) Stressing of tendons and transfer of prestress shall be carried out at a gradual and
    as

    steady rate. The force in the tendons shall be obtained from readings on a recently
    calibrated load cell or pressure gauge incorporated in the equipment. The extension of
    the tendons under the agreed total forces shall be within 5 % of the agreed calculated
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    extension.
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    2 Concrete Strength
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    (a) The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to
    be able to demonstrate by testing two cubes at a time, with approved intervals between
    pairs of cubes, that the specified transfer strength of the concrete has been reached.
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    (b) Unless otherwise permitted, concrete shall not be stressed until two test cubes attain
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    the specified transfer strength.


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    3 Post-Tensioned Piles

    (a) Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

    4 Grouting Procedure

    (a) Grout shall be mixed for a minimum of 2 min and until a uniform consistency is
    obtained.
    (b) Ducts shall not be grouted when the air temperature in the shade is lower than 3 C.

    (c) Before grouting is started all ducts shall be thoroughly cleaned by means of
    compressed air.
    (d) Grout shall be injected near the lowest point in the duct in one continuous operation
    and allowed to flow from the outlet until the consistency is equivalent to that of the
    grout being injected.
    (e) Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 8
    Part 04: Deep Foundations

    5 Grout

    (a) Unless otherwise directed or agreed by the Engineer


    (i) the grout shall consist only of ordinary Portland cement, water and approved
    admixtures; admixtures containing chlorides or nitrates shall not be used
    (ii) the grout shall have a water/cement ratio as low as possible consistent with the
    necessary workability, and the water/cement ratio shall not exceed 0.45 unless
    an approved mix containing an expanding agent is used
    (iii) the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess
    of 4% maximum, when measured at 18 C in a covered glass cylinder
    approximately 100 mm in diameter with a height of grout of approximately 100
    mm, and the water shall be reabsorbed after 24 h.

    6 Records

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    (a) The Contractor shall keep detailed records of times of tensioning, measured

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    extensions, pressure gauge readings or load cell readings and the amount of pull-in at

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    each anchorage. Copies of these records shall be supplied to the Engineer within
    such reasonable time from completion of each tensioning operation as may be
    required, and in any case not later than noon on the following working day.
    (b)
    ta
    The Contractor shall keep records of grouting, including the date, the proportions of
    qa
    the grout and any admixtures used, the pressure, details of interruption and topping up
    required. Copies of these records shall be supplied to the Engineer within such
    reasonable time after completion of each grouting operation as may be required, and
    as

    in any case not later than noon on the following working day.
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    4.1.6 Driving Piles


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    1 Strength of Piles
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    (a) Piles shall not be driven until the concrete has achieved the specified strength.

    2 Leaders and Trestles


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    (a) At all stages during driving and until incorporation into the substructure, the pile shall
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    be adequately supported and restrained by means of leaders, trestles, temporary


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    supports or other guide arrangements to maintain position and alignment and to


    prevent buckling. These arrangements shall be such that damage to the pile does not
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    occur.

    3 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment. Where designated, dynamic evaluation and analysis
    shall be provided.
    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile unless otherwise approved by the Engineer. For other types of hammer the
    energy delivered to the pile per blow shall be at least equivalent to that of a drop
    hammer of the stated mass. Drop hammers shall not be used from floating craft in
    such a manner as to cause instability of the craft or damage to the pile.

    4 Length of Piles

    (a) The length of pile to be driven in any location shall be approved prior to the
    commencement of driving.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 9
    Part 04: Deep Foundations

    5 Driving Procedure and Redrive Checks

    (a) The driving of each pile shall be continuous until the specified depth or resistance
    (set), or both, has been reached. In the event of unavoidable interruption to driving,
    the pile will be accepted provided it can subsequently be driven to the specified depth
    or resistance (set), or both, without damage. A follower shall not be used unless
    approved, in which case the Engineer will require the set where applicable to be
    revised in order to take into account reduction in the effectiveness of the hammer blow.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    driving characteristics is noted. A detailed record of the driving resistance over the full
    length of the nearest available pile shall be taken if required.
    (c) At the start of the work in a new area or section, a detailed driving record shall be
    made over the full length of the first pile and during the last 3 m of subsequent piles
    until consistency of behaviour is established. Where required, detailed driving records

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    shall also be made for 5 % of the piles driven, the locations of such piles being
    specified by the Engineer.

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    (d) The Contractor shall give adequate notice and provide all necessary facilities to enable
    the Engineer to check driving resistance. A set or resistance measurement shall be

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    taken only in the presence of the Engineer unless otherwise approved.
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    (e) Redrive checks, if required, shall be carried out to an approved procedure.

    6 Final Set
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    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
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    penetration in millimetres per 10 blows or as the number of blows required to produce


    a penetration of 25 mm.
    er

    (b) When a final set is being measured, the following requirements shall be met:
    ov

    (i) The exposed part of the pile shall be in good condition without damage or
    distortion.
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    (ii) The helmet, dolly and any packing shall be in sound condition.
    it

    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    et

    be flat and at right angles to the pile and hammer axis, and the head of the pile
    protected against damage from hammer impact.
    m

    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded, if required.

    7 Preboring

    (a) If preboring is specified, the diameter and depth of prebore shall be as designated.

    8 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 10
    Part 04: Deep Foundations

    4.1.7 Risen Piles

    (a) Piles shall be driven in an approved sequence to minimise the detrimental effects of
    heave and lateral displacement of the ground.
    (b) When required, levels and measurements shall be taken to determine the movement
    of the ground or of any pile resulting from the driving process.
    (c) When a pile has risen as a result of adjacent piles being driven, the Engineer may call
    for redriving or other testing to demonstrate that the performance of the pile is
    unimpaired. If required, the Contractor shall make proposals for correcting
    detrimentally affected piles and for avoidance or control of heave effects in subsequent
    work.

    4.1.8 Repair and lengthening of piles

    .
    1 Repair of Damaged Pile Heads

    l
    .l.
    (a) If it is necessary to repair the head of a pile during driving, the Contractor shall carry

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    out such repair in an approved way which allows the pile-driving to be completed
    without further damage. If the driving of a pile has been accepted but sound concrete
    of the pile is below the required cut-off level, the pile shall be made good to the cut-off
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    level, using an approved method so that it will safely withstand the imposed design
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    load.

    2 Lengthening of Reinforced and Prestressed Concrete Piles


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    (a) Any provision for lengthening piles incorporated at the time of manufacture shall be as
    designed or approved.
    se

    (b) If no provision for lengthening piles was incorporated at the time of manufacture, any
    method for lengthening shall be such that splices are capable of safely resisting the
    er

    stresses during driving and under service load and shall be subject to approval.
    ov

    3 Driving Repaired or Lengthened Piles

    (a) Repaired or lengthened piles shall not be driven until the added concrete has reached
    o

    the specified strength of the concrete of the pile.


    it

    4.1.9 Cutting off pile heads


    et
    m

    1 Unless otherwise directed by the Engineer, when the driving of a pile has been approved the
    concrete of the head of the pile shall be cut off to the designated level. The length of splice
    reinforcing bars projecting above this level shall be as designated.

    2 Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
    cracked or defective concrete shall be cut away and the pile repaired in an approved manner
    to provide a full and sound section at the cut-off level.

    4.2 PRECAST REINFORCED CONCRETE SEGMENTAL PILES

    4.2.1 Scope

    1 This Part applies to piles made of elements cast at a precasting works away from the site,
    where work cannot normally be closely supervised by the Engineer. The elements are joined
    together as necessary on site during driving using special proven steel joints incorporated
    into the pile elements when cast.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 11
    Part 04: Deep Foundations

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 5, Concrete.
    4.2.2 References

    1 The following Standards are referred to in this Part:


    Eurocode 7, EN1997-1, Section 7 Pile foundation
    BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates
    BS 3100,.....................Steel castings for general engineering purposes
    BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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    .l.
    BS 8110,.....................Structural use of concrete.

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    4.2.3 Submittals

    1 The Contractor shall order the piles to suit the construction programme and seek the

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    Engineer's approval before placing the order. When preliminary piles are specified the
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    approval for the piles for the main work will not necessarily be given until the results of the
    driving and tests on preliminary piles have been received and evaluated.
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    4.2.4 Quality Assurance


    se

    1 A certificate of quality from the pile manufacturer shall be provided to the Engineer when
    required stating that the designated requirements have been fulfilled during manufacture.
    er

    2 Each pile element shall be marked in such a manner that it can be identified with the records
    ov

    of manufacture, which shall state the date of casting, the cement type, concrete grade,
    element length and any other relevant data. On delivery, the pile elements shall be
    accompanied by records of manufacture.
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    4.2.5 Tolerances in Pile Dimensions


    et

    1 The cross-sectional dimensions of the pile shall be not less than those designated.
    m

    2 The head of a pile element or the end of the pile upon which the hammer acts shall be
    square to the pile axis within a tolerance of 1 in 50.

    3 Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The
    centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

    4 Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m
    long joining two points on that face, nor shall the centre of area of the pile at any cross-
    section along its length deviate by more than 1/500 of the pile length from a line joining the
    centres of area at the ends of the element. Where a pile element is less than 3 m long the
    permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in
    accordance with actual length.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 12
    Part 04: Deep Foundations

    4.2.6 Handling, Transportation, Storage and Acceptance of Piles

    1 The method and sequence of lifting, handling, transporting and storing piles shall be such as
    to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting
    and support points shall be used. During transport and storage, piles shall be appropriately
    supported under the marked lifting points or fully supported along their length.

    2 All pile elements within a stack shall be in groups of the same length. Packing of uniform
    thickness shall be provided between piles at the lifting points.

    3 Concrete shall at no time be subjected to loading, including its own weight, which will induce
    a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the
    specified strength, whichever is the less. For this purpose the assessment of the strength of
    the concrete and of the stresses produced by the loads shall be subject to the approval of the
    Engineer.

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    .l.
    4 A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm.

    rw
    The measurement shall be made with the pile in its working attitude.

    4.2.7 Materials and components

    1 Fabricated Steel Components ta


    qa
    (a) In the manufacture of jointed precast concrete segmental piles, fabricated steel
    components shall comply with BS 7613 grades 43A or 50A, cast steel components
    as

    with BS 3100 grade A, and ductile iron components with BS 2789.


    se

    2 Pile Splices
    er

    (a) The splice joints shall be close-fitting face to face and the locking method shall be
    such as to hold the faces in intimate contact. The design and manufacture of the
    ov

    splicing system shall be approved by the Engineer prior to the commencement of the
    Contract.
    o

    (b) A spliced pile shall be capable of withstanding the same driving stresses or service
    it

    axial loads, moments and shear stresses as a single unspliced pile of the same cross-
    et

    sectional dimensions and materials.


    m

    (c) The welding of a joint to main reinforcement in lieu of a lapped connection with
    projecting bars affixed to the joint will not be permitted.

    3 Pile Toes

    (a) Pile toes shall be constructed so as to ensure that damage is not caused to the pile
    during installation. Where fixity is required or socketing into rock, or in other
    circumstances, an approved shoe may be required.

    4 Pile Head Reinforcement

    (a) Where the pile head is not furnished with a joint, it shall be so reinforced or banded as
    to prevent bursting of the pile under driving conditions.

    5 Main Reinforcement

    (a) The main longitudinal reinforcing bars shall be in one continuous length. Splicing of
    bars will not be permitted except at element ends.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 13
    Part 04: Deep Foundations

    (b) Concrete cover to steel reinforcement shall be in accordance with the requirements of
    BS 8110.
    (c) In very aggressive ground or exposure conditions, cover greater than 25 mm may be
    required, but alternative protection methods may be approved.

    6 Formwork

    (a) If a pile is constructed with a shaped point or shoe, then the end of the pile shall be
    symmetrical about the longitudinal axis of the pile.
    (b) Holes for handling or pitching, where provided in the pile, shall be lined with steel
    tubes; alternatively, approved inserts may be cast in.
    (c) Formwork shall be robust, clean and so constructed as to prevent loss of grout or
    aggregate from the wet concrete and ensure the production of uniform pile sections.
    The piles are to be removed from the formwork carefully so as to prevent damage.

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    4.2.8 Driving piles

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    1 Strength of Piles

    (a)
    ta
    Piles shall not be driven until the concrete has achieved the specified characteristic
    strength.
    qa
    2 Leaders and Trestles
    as

    (a) At all stages during driving and until incorporation into the substructure, the pile shall
    be adequately supported and restrained by means of leaders, trestles, temporary
    se

    supports or other guide arrangements to maintain position and alignment and to


    prevent buckling. These arrangements shall be such that damage to the pile does not
    er

    occur.

    3 Performance of Driving Equipment


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    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    o

    energy of the driving equipment. Where required in the particular specification,


    dynamic evaluation and analysis shall be provided.
    it
    et

    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile at the moment of driving unless otherwise approved by the Engineer. For
    m

    other types of hammer, the energy delivered to the pile per blow shall be at least
    equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be
    used from floating craft in such a manner as to cause instability of the craft or damage
    to the pile.

    4 Length of Piles

    (a) The length of pile supplied to be driven in any location and any additional lengths to be
    added during driving shall he approved prior to the commencement of pile-driving.
    During the execution of the Works, any changes to the supplied lengths shall be
    approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 14
    Part 04: Deep Foundations

    5 Driving Procedure and Redrive Checks

    (a) Except when making field splices, the driving of each pile shall he continuous until the
    specified depth or resistance (set), or both, has been reached. In the event of
    unavoidable interruption to driving, the pile will be accepted provided it can
    subsequently be driven to the specified depth or resistance (set), or both, without
    damage. A follower shall only be used when approved, in which case the Engineer will
    require the set where applicable to be revised in order to take into account reduction in
    the effectiveness of the hammer blow.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    driving characteristics is noted. A detailed record of the driving resistance over the full
    length of the nearest available pile shall be taken if required.
    (c) At the start of the work in a new area or section a detailed driving record shall be made
    over the full length of the first pile and during the last 3 m of subsequent piles until

    l .
    consistency of behaviour is established. Where required, detailed driving records shall

    .l.
    also be made for 5 % of the piles driven, the positions of such piles being specified by

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    the Engineer.
    (d) The Contractor shall give adequate notice and provide all necessary facilities to enable

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    the Engineer to check driving resistance. A set or resistance measurement shall be
    taken only in the presence of the Engineer unless otherwise approved.
    qa
    (e) Redrive checks, if required, shall be carried out to an approved procedure.

    6 Final Set
    as

    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
    se

    penetration in millimetres per ten blows or as the number of blows required to produce
    a penetration of 25 mm.
    er

    (b) When a final set is being measured, the following requirements shall be met:
    ov

    (i) The exposed part of the pile shall be in good condition, without damage or
    distortion.
    o

    (ii) The helmet, dolly and any packing shall be in sound condition.
    it

    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    et

    be flat and at right angles to the pile and hammer axis.


    m

    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded if required.

    7 Preboring

    (a) If preboring is specified, the diameter and depth of prebore shall be as designated.

    8 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.

    4.2.9 Risen Piles

    (a) Piles shall be driven in an approved sequence to minimise the detrimental effects of
    heave and lateral displacement of the ground.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 15
    Part 04: Deep Foundations

    (b) When required, levels and measurements shall be taken to determine the movement
    of the ground or of any pile resulting from the driving process.
    (c) When a pile has risen as a result of adjacent piles being driven, the Engineer may call
    for redriving or other testing to demonstrate that the performance of the pile is
    unimpaired. If required, the Contractor shall make proposals for correcting piles
    detrimentally affected and for avoidance or control of heave effects in subsequent
    work.

    4.2.10 Repair and lengthening of piles

    1 Repair of Damaged Pile Heads

    (a) If it is necessary to repair the head of a pile during driving, the Contractor shall carry
    out such repair in an approved way which allows the driving of the pile to be completed
    without further damage. If the driving of a pile has been accepted but sound concrete

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    of the pile is below the required cut-off level, the pile shall be made good to the cut-off

    .l.
    level, using an approved method so that it will safely withstand the imposed design

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    load.

    2 Lengthening of Piles

    (a) ta
    Where piles are required to be driven to depths exceeding those expected, leaving
    qa
    insufficient projection for bonding into the following works, the piles shall be extended
    or replaced as required by the Engineer using approved materials and methods.
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    4.2.11 Cutting off pile heads


    se

    1 Unless otherwise specified, when the driving of a pile has been approved the concrete of the
    head of the pile shall be cut off to the designated level. The length of splice reinforcing bars
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    projecting above this level shall be as designated.


    ov

    2 Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
    cracked or defective concrete shall be cut away and the pile repaired in an approved manner
    to provide a full and sound section at the cut-off level.
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    4.3 BORED CAST IN PLACE PILES


    et
    m

    4.3.1 Scope

    1 This Part applies to bored piles in which the pile bore is excavated by rotary or percussive
    means, or both, using short augers, buckets, grabs or other boring tools to advance the open
    bore. Where the open bore is unstable, temporary or permanent casing or bentonite
    suspension may be used to support the wall of the bore prior to concreting.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation


    Section 5, Concrete
    QCS 2014 Section 04: Foundations and Retaining Structures Page 16
    Part 04: Deep Foundations

    4.3.2 References

    1 The following codes of practice are referred to in this Part:


    BS 5573,.....................Code of practice for safety precautions in the construction of large
    diameter boreholes for piling and other purposes
    BS 5930,.....................Code of practice for site investigation.

    4.3.3 Quality Assurance

    1 Inspection

    (a) Each pile bore which does not contain standing water or drilling fluid shall be inspected
    directly or indirectly prior to concrete being placed in it. This inspection shall be carried
    out from the ground surface in the case of piles of less than 750 mm diameter.

    .
    Torches or other approved means of lighting, measuring tapes, and a means of

    l
    .l.
    measuring verticality shall be provided. For piles of 750 mm diameter or larger,
    equipment shall be provided, by the Contractor to enable his representatives and the

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    Engineer to descend into the bore for the purpose of inspection. Any method of
    descent and the equipment used shall comply with the requirements of BS 5573.

    2 Cleanliness of pile bases


    ta
    qa
    (a) On completion of boring and where inspection of a dry pile bore indicates the
    necessity, loose, disturbed or softened soil shall be removed from the bore. Where
    as

    pile bores contain water or drilling fluid, a cleaning process shall be employed before
    concrete is placed. Large debris and accumulated sediment shall be removed using
    appropriate approved methods, which shall be designed to clean while at the same
    se

    time minimising ground disturbance below the pile bases. Water or drilling fluid shall
    be maintained at such levels throughout and following the cleaning operation that
    er

    stability of the bore is preserved.


    ov

    3 Samples and Testing

    (a) If required in the Contract, soil, rock or groundwater samples shall be taken or soil
    o

    tests carried out in-situ while the pile is being bored. The samples shall be taken to an
    it

    approved laboratory for testing as specified.


    et

    (b) The taking of samples and all subsequent handling, transporting and testing shall be
    m

    carried out in accordance with Section 3, Ground Investigation.

    4.3.4 Materials

    1 Permanent Casings

    (a) Permanent casings shall be as specified.

    2 Drilling Fluid Supply

    (a) A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
    powder showing the properties of each consignment delivered to the Site. This
    certificate shall be made available to the Engineer on request. The properties to be
    given by the manufacturer are the apparent viscosity range (in Pascal seconds) and
    the gel strength range (in Pascal) for solids in water.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 17
    Part 04: Deep Foundations

    3 Drilling Fluid Mixing

    (a) Bentonite shall be mixed thoroughly with clean fresh water to make a suspension
    which will maintain the stability of the pile bore for the period necessary to place
    concrete and complete construction. The temperature of the water used in mixing the
    bentonite suspension, and of the suspension when supplied to the borehole, shall be
    not lower than 5 C.
    (b) Where saline or chemically contaminated groundwater occurs, special precautions
    shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh
    water so as to render it suitable in all respects for the construction of piles.

    4 Drilling Fluid Tests

    (a) The frequency of testing drilling fluid and the method and procedure of sampling shall
    be proposed by the Contractor for approval prior to the commencement of the work.
    The frequency may subsequently be varied as required, depending on the consistency
    of the results obtained, subject to approval.

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    (b) Control tests shall be carried out on the bentonite suspension, using suitable
    apparatus. The density of freshly mixed bentonite suspension shall be measured daily

    rw
    as a check on the quality of the suspension being formed. The measuring device shall
    be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear
    strength and pH value shall be applied to bentonite supplied to the pile bore. For

    ta
    average soil conditions the results shall generally be within the ranges in Table 4.2.
    qa
    Table 4.2.Tests on Bentonite
    Property to be measured Range of results at 20 C Test method
    as

    Density Less than 1.10 g/ml Mud density balance


    se

    30 - 90 s Marsh cone method


    Viscosity or
    er

    less than 0.020 Pa s Fann viscometer*


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    1.4-10 Pa Shear meter


    Shear strength
    Or
    (10 minute gel strength)
    4-40 Pa Fann viscometer
    o

    pH indicator paper strips


    pH 9.5 - 12
    it

    or electrical pH meter
    et

    * Where the Fann viscometer is specified, the fluid sample should be screened by a
    number 52 sieve (300 m) prior to testing.
    m

    (c) The tests shall be carried out until a consistent working pattern has been established
    account being taken of the mixing process, any blending of freshly mixed bentonite
    suspension and previously used bentonite suspension, and any process which may be
    used to remove impurities from previously used bentonite suspension. When the
    results show consistent behaviour, the tests for shear strength and pH value may be
    discontinued, and tests to determine density and viscosity shall be carried out as
    agreed with the Engineer. In the event of a change in the established working pattern,
    tests for shear strength and pH value shall be reintroduced for a period if required.

    4.3.5 Boring

    1 Boring Near Recently Cast Piles

    (a) Piles shall not be bored so close to other recently completed piles as to damage them.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 18
    Part 04: Deep Foundations

    2 Temporary Casings

    (a) Temporary casing of approved quality or an approved alternative method shall be used
    to maintain the stability of a pile bore which might otherwise collapse.
    (b) Temporary casings shall be free from significant distortion. They shall be of uniform
    cross-section throughout each continuous length. During concreting they shall be free
    from internal projections and encrusted concrete which might adversely affect the
    proper formation of piles.
    (c) The use of a vibrator to insert and withdraw temporary casing may be permitted by the
    Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent
    Structures of this section and to the method not causing disturbance of the ground
    which would adversely affect the construction or the capacity of piles.
    (d) Where piles are bored under water or bentonite suspension in an unlined state, the

    .
    insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing

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    .l.
    concrete will not be permitted.

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    (e) Where permanent casing is specified to ensure the integrity of a pile, the Contractor
    shall submit for approval his proposals regarding the method of installation.

    3 Stability of Pile
    ta
    qa
    (a) Where boring takes place through unstable water-bearing strata, the process of
    excavation and the depth of temporary casing employed shall be such that soil from
    outside the area of the pile is not drawn into the pile section and cavities are not
    as

    created outside the temporary casing as it is advanced.


    (b) Where the use of drilling fluid is specified or approved for maintaining the stability of a
    se

    bore, an adequate temporary casing shall be used in conjunction with the method so
    as to ensure stability of the strata near ground level until concrete has been placed.
    er

    During construction the level of drilling fluid in the pile excavation shall be maintained
    ov

    within the cased or stable bore so that it is not less than 1.0 m above the level of
    external standing groundwater at all times.
    o

    (c) In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be
    backfilled without delay and the instructions of the Engineer shall be obtained before
    it

    boring at that location is resumed.


    et
    m

    4 Spillage and Disposal of Drilling Fluid

    (a) All reasonable steps shall be taken to prevent the spillage of bentonite suspension on
    the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be
    removed from the Site without undue delay. Any disposal of bentonite shall comply
    with the regulations of the local controlling authority.

    5 Pumping from Pile Bores

    (a) Pumping from pile bores shall not be permitted unless the bore has been sealed
    against further water entry by casing or unless the soil is stable and will allow pumping
    to take place without ground disturbance below or around the pile.

    6 Continuity of Construction

    (a) For a pile constructed in a stable cohesive soil without the use of temporary casing or
    other form of support, the pile shall be bored and the concrete shall be placed without
    such delay as would lead to significant impairment of the soil strength.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 19
    Part 04: Deep Foundations

    7 Enlarged Pile Bases

    (a) A mechanically formed enlarged base shall be no smaller than the dimensions
    specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the
    shaft diameter. The sloping surface of the frustum forming the enlargement shall make
    an angle to the axis of the pile of not more than 35 .

    4.3.6 Extraction of casing

    1 Workability of Concrete

    (a) Temporary casings shall be extracted while the concrete within them remains
    sufficiently workable to ensure that the concrete is not lifted. During extraction the
    motion of the casing shall be maintained in an axial direction relative to the pile.

    2 Concrete Level

    l .
    .l.
    (a) When the casing is being extracted, a sufficient quantity of concrete shall be

    rw
    maintained within it to ensure that pressure from external water, drilling fluid or soil is
    exceeded and that the pile is neither reduced in section nor contaminated.
    (b) The concrete level within a temporary casing shall be topped up where necessary
    ta
    during the course of casing extraction in such a way that the base of the casing is
    qa
    always below the concrete surface until the casting of the pile has been completed.
    (c) Adequate precautions shall be taken in all cases where excess heads of water or
    as

    drilling fluid could occur as the casing is withdrawn because of the displacement of
    water or fluid by the concrete as it flows into its final position against the walls of the
    pile bore. Where two or more discontinuous lengths of casing (double casing) are
    se

    used in the construction the proposed method of working shall be approved.


    er

    3 Pile Head Casting Level Tolerances


    ov

    (a) For piles cast in dry bores using temporary casing and without the use of a permanent
    lining, pile heads shall be cast to a level above the specified cut-off so that, after
    trimming, a sound concrete connection with the pile can be made. The casting level
    o

    shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be
    it

    above the original ground level. No pile shall be cast with its head below standing
    et

    water level unless approved measures are taken to prevent inflow of water causing
    m

    segregation of the concrete as temporary casing is extracted, and, where approved by


    the Engineer, the groundwater level for each pile shall be treated as the cut-off level for
    the purpose of calculating tolerance.
    (b) For piles cast in dry bores within permanent lining tubes or permanent casings, or
    where their cut-off levels are in stable ground below the base of any casing used, pile
    heads shall be cast to a level above the specified cut-off so that, after trimming, a
    sound concrete connection with the pile can be made. The casting level shall be within
    the tolerance above the cut-off level shown in Table 4.4, but shall not be above the
    original ground level.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 20
    Part 04: Deep Foundations

    (c) For piles cast under water or drilling fluid, the pile heads shall be cast to a level above
    the specified cut-off so that, after trimming to remove all debris and contaminated
    concrete, a sound concrete connection with the pile can be made. The casting level
    shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be
    above the commencing surface level. Cut-off levels may be specified below the
    standing groundwater level, and where this condition applies the borehole fluid level
    shall not be reduced below the standing groundwater level until the concrete has set.
    (d) Where the cut-off level of piles lies at depths greater than 10 m below the original
    ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after
    discussion with the Contractor and before the commencement of the piling to take
    account of the special conditions which apply.
    Table 4.3
    Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing

    .
    and Without the Use of a Permanent Lining

    l
    .l.
    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m

    rw
    H, m
    0.3 + H/12 + C/8
    where C = length of temporary casing
    0.15-10.00
    ta below the commencing surface*
    qa
    * If H is greater than C, then this tolerance is no longer applicable and the tolerances in
    Table 4.4 will apply.
    as

    Table 4.4
    Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining
    se

    Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the
    Base of Any Casing Used
    er
    ov

    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m
    H, m
    o

    0.15-10.00 0.3 + H/10


    it

    Table 4.5
    et

    Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid**
    m

    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m
    H, m

    1.0 + H /12 + C/8


    0.15-10.00 where C = length of temporary casing
    below the commencing surface

    ** In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
    tolerance is given by deletion of the casing term C/8 in the table.

    4 Water levels

    (a) During extraction of temporary casings, where circumstances are such that newly
    placed unset concrete is brought into contact with external groundwater, precautions
    shall be taken to ensure that the internal concrete pressure at all levels within the pile
    exceeds the external groundwater pressure.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 21
    Part 04: Deep Foundations

    5 Temporary backfilling above pile casting level

    (a) After each pile has been cast, any empty bore remaining shall be protected and shall
    be carefully backfilled as soon as possible with approved materials.

    6 Disposal of excavated material

    (a) Disposal of excavated material shall be carried out by the Contractor as necessary to
    facilitate the Works and to the satisfaction of the Engineer.

    7 Cutting off pile heads

    (a) When cutting off and trimming piles to the specified cut-off level, the Contractor shall
    take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked
    or defective concrete shall be cut away and the pile repaired in an approved manner to
    provide a full and sound section at the cut-off level

    4.4 BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS

    l .
    .l.
    AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER
    STEMS

    rw
    4.4.1 Scope

    1 ta
    This Part applies to bored piles which employ a continuous flight auger for both advancing
    qa
    the bore and maintaining its stability. The spoil-laden auger is not removed from the ground
    until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed
    auger to replace the excavated soil.
    as

    2 Related Sections and Parts are as follows:


    se

    This Section
    er

    Part 1, .............. General Requirements for Piling Works


    ov

    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation.


    o

    Section 5, Concrete
    it
    et

    4.4.2 Materials
    m

    1 Concrete Mix Design and Workability

    (a) Where not otherwise stated in this Part, the concrete shall comply with Section 5. The
    design and workability of concrete to be used in the formation of a pile shall produce a
    mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless
    3
    otherwise approved and a minimum cement content of 340 kg/m . The mix shall be
    designed so that segregation does not occur during the placing process, and bleeding
    of the mix shall be minimised.

    2 Grout Mix Design and Workability

    (a) Mix design of grout shall be subject to approval. Cement, water and aggregates for
    grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm
    nominal size and shall be rounded and evenly graded.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 22
    Part 04: Deep Foundations

    (b) The workability of grout mixes, where used, shall be measured by a suitable and
    approved means. The procedure for monitoring the suitability of grout throughout the
    Works shall be stated in writing to the Engineer before beginning of the Works and
    shall be subject to approval.
    (c) Additives to the grout shall require prior approval of the Engineer.

    3 Reinforcement

    (a) All reinforcement shall be placed with the minimum delay after the completion of the
    concreting or grouting operation. It shall be designed and fabricated in cages to permit
    it to be placed in the correct position and to the depth specified through the concrete or
    grout of the pile. Suitable approved spacers shall be provided to maintain the specified
    concrete or grout cover to steel.
    (b) The transverse reinforcement of any reinforcing cage shall be approved and may

    .
    consist of either spirals, hoops or links.

    l
    .l.
    (c) Longitudinal main steel reinforcement shall be continuous over the specified length.

    rw
    Where splices are necessary, the number of laps shall be kept to a minimum and bars
    shall be welded or joined together in an approved manner.
    (d)
    ta
    Reinforcement shall be supported and centred so that it will provide the required
    projection above the cut-off level, and the proper concrete cover.
    qa
    4.4.3 Boring
    as

    1 General
    se

    (a) During uncased boring with continuous flight auger, the feed forward and speed
    (revolutions per minute) are to be adjusted according to the soil conditions in a way
    er

    that the excavation of soil will be limited to a quantity that the lateral support of the
    uncased borehole wall will be ensured.
    ov

    2 Boring Near Recently Cast Piles


    o

    (a) Piles shall not be bored so close to other piles which have recently been cast as to
    it

    damage them.
    et

    3 Removal of Augers from the Ground


    m

    (a) Augers shall not be extracted from the ground during the boring or construction of a
    pile in such a way that an open unsupported bore or inflow of water into the pile section
    would result. While withdrawing the continuous flight auger, the auger shall be rotated
    in the same direction as during drilling into the soil or shall be withdrawn without
    rotation.

    4 Depth of Piles

    (a) Any failure of a pile to reach the designated depth shall be reported to the Engineer
    without delay and a full statement of the reasons given.

    5 Suitability of Boring Equipment

    (a) The piles shall be bored using approved and suitable equipment capable of
    penetrating the ground without drawing surrounding soils laterally into the pile bore.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 23
    Part 04: Deep Foundations

    4.4.4 Placing of concrete or grout

    1 Equipment for Supply of Concrete or Grout to Piles

    (a) Grout or concrete shall be supplied to the pile through suitable tubing and the hollow
    auger stem. All pipe fitments and connections shall be so constructed that grout does
    not leak during the injection process.

    2 Commencement of Concrete or Grout Supply to Each Pile

    (a) The base of the auger stem shall be fitted with a suitable means of sealing it against
    ingress of water and soil until concrete or grout placing begins.
    (b) At the beginning of concrete or grout placement this sealing device shall be removed
    by the application of concrete or grout pressure. Care shall be taken to ensure that the
    auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water
    inflow and soil movement at the base of the auger are minimised. The technique and

    .
    equipment used to initiate and maintain the concrete or grout flow shall be such that a

    l
    .l.
    pile of the full specified cross-section is obtained from the maximum depth of boring to
    the final pile cut-off level.

    rw
    3 Rate of Supply of Concrete or Grout

    (a) The concrete or grout shall be supplied to the pile at a sufficient rate during auger
    ta
    withdrawal to ensure that a continuous monolithic shaft of the full specified cross-
    qa
    section is formed, free from debris or any segregated concrete or grout.
    (b) The rate of withdrawal of the auger, the injection pressures and the rate of supply of
    concrete or grout shall be measured and recorded throughout the phase of auger
    as

    withdrawal for each pile.


    (c) The Contractor shall submit proposals for his method of monitoring construction for
    se

    approval before beginning the Works.


    er

    4 Completion of Piles

    (a) If the concrete or grout placing in any pile cannot be completed in the normal manner,
    ov

    then the pile shall be rebored before concrete has hardened and shall be completely
    replaced.
    o

    5 Casting Level of Pile Head


    it
    et

    (a) Concrete or grout shall be cast to the original ground level in all cases, and the
    reinforcing cage set, as appropriate.
    m

    4.4.5 Cutting off pile heads

    1 When cutting off and trimming piles to the specified cut-off level, the Contractor shall take
    care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or
    contaminated, cracked or defective concrete shall be cut away and the pile repaired in an
    approved manner to provide a full and sound section up to the cut-off level.

    4.5 DRIVEN CAST IN PLACES PILES

    4.5.1 Scope

    1 This Part applies to piles for which a permanent casing of steel or concrete is driven,
    reinforcement placed within it if required, and the casing filled with concrete. It also applies to
    piles in which a temporary casing is driven, reinforcement placed within it and the pile formed
    in the ground by filling the temporary casing with concrete before and during its extraction.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 24
    Part 04: Deep Foundations

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 5, Concrete
    Section 3, Ground Investigation.
    4.5.2 Submittals

    1 Where the Contractor wishes to form a pile with an enlarged base, details of the proposed
    method of forming the base and the materials to be used shall be submitted at the time of
    tendering.

    4.5.3 Quality Assurance

    l .
    .l.
    1 Before placing concrete in a pile casing, the Contractor shall check in an approved manner

    rw
    that the casing is undamaged, and free from water or other foreign matter. In the event of
    water or foreign matter having entered the pile casing, either the casing shall be withdrawn,
    repaired if necessary and re-driven, or other action shall be taken as may be approved to
    continue the construction of the pile.
    ta
    qa
    4.5.4 Materials
    as

    1 Permanent Casings

    (a) Permanent casings shall be as specified. Where a permanent casing is to be made


    se

    from a series of short sections it shall be designed and placed so as to produce a


    continuous water-free shaft. The dimensions and quality of the casing shall be
    er

    adequate to withstand the stresses caused by handling and driving without damage or
    distortion.
    ov

    2 Temporary Casings
    o

    (a) Temporary casings shall be free from significant distortion. They shall be of uniform
    it

    external cross-section throughout each continuous length. During concreting they


    et

    shall be free from internal projections and encrusted concrete which might prevent the
    m

    proper formation of piles.

    3 Pile Shoes

    (a) Pile shoes shall be manufactured from durable material capable of withstanding the
    stresses caused by driving without damage, and shall be designed to give a watertight
    joint during construction.

    4 Reinforcement

    (a) This type of pile shall normally be reinforced over its full length unless permanently
    cased. The use of shorter reinforcement in piles which are not permanently cased
    shall be subject to the approval of the Engineer.
    (b) The number of splices in longitudinal steel bars shall be kept to a minimum. The full
    strength of each bar shall be effective across each splice, which shall be made so that
    there is no detrimental displacement of the reinforcement during the construction of
    the pile.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 25
    Part 04: Deep Foundations

    4.5.5 Driving piles

    1 Piling Near Recently Cast Piles

    (a) Casings shall not be driven or piles formed so close to other piles which have recently
    been cast as to damage them.

    2 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment
    (b) Drop hammers shall not be used from floating craft in such a manner as to cause
    instability of the craft.

    3 Length of Piles

    l .
    (a) The length of pile to be driven in any location shall be approved.

    .l.
    rw
    4 Driving Procedure

    (a) Each pile casing shall be driven continuously until the specified or approved depth or

    ta
    resistance (set), or both, has been reached. In the event of unavoidable interruption to
    driving, the pile will be accepted provided on resumption the casing can be driven to
    qa
    the specified depth or resistance (set), or both, without damage.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    as

    driving characteristics is encountered. A detailed record of the driving resistance over


    the full length of the nearest available subsequent pile shall be taken if required.
    se

    (c) At the start of the work in a new area or section a detailed driving record shall be made
    over the full length of the first pile to be installed and over the last 3 m of the driving of
    er

    subsequent piles until consistency of behaviour is established. Where required,


    detailed driving records shall also be made for 5 % of the piles driven, the positions of
    ov

    such piles being specified by the Engineer.


    (d) The Contractor shall give adequate notice and provide all facilities to enable the
    o

    Engineer to check driving resistance. A set shall be taken only in the presence of the
    it

    Engineer unless otherwise approved.


    et

    5 Final Set
    m

    (a) Where piles are driven to a set, the final set of each pile, pile shell or casing shall be
    recorded either as the penetration in millimetres per ten blows or as the number of
    blows required to produce a penetration of 25 mm.
    (b) When a final set is being measured, the following requirements shall be met:
    (i) The exposed part of the pile casing shall be in good condition, without damage
    or distortion.
    (ii) The dolly, helmet and packing, if any, shall be in sound condition.
    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    be flat and at right angles to the pile and hammer axis.
    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) Temporary compression of the pile casing shall be recorded if required.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 26
    Part 04: Deep Foundations

    6 Preboring

    (a) If preboring is specified the pile casing shall be pitched after preboring to the
    designated depth and diameter.

    7 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved by the Engineer

    8 Internal Drop Hammer

    (a) Where a casing for a pile without an enlarged base is to be driven by an internal drop
    hammer, a plug consisting of concrete grade 20 with a water/cement ratio not
    exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of
    not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to

    .
    ensure that this height of driving plug is maintained in the casing throughout the period

    l
    .l.
    of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of

    rw
    normal driving or after 45 min of hard driving, or, should the driving of a pile be
    interrupted for 30 min or longer, fresh concrete shall be added prior to driving being
    resumed.

    4.5.6 Risen Piles ta


    qa
    1 Piles shall be driven in an approved sequence to minimise any detrimental effects of heave
    and lateral displacement of the ground.
    as

    2 When required, levels and measurements shall be taken to determine the movement of the
    se

    ground or any pile resulting from the driving process.


    er

    3 When a pile has risen with detrimental effects as a result of adjacent piles being driven the
    Contractor shall, if required, submit to the Engineer his proposals for correcting or
    ov

    compensating for this and for avoidance or control of heave effects in subsequent work.
    o

    4.5.7 Extraction of casing


    it

    1 Workability of Concrete
    et
    m

    (a) Temporary casings shall be extracted while the concrete within them remains
    sufficiently workable to ensure that the concrete is not lifted.

    2 Concrete Level

    (a) When the casing is being extracted, a sufficient quantity of concrete shall be
    maintained within it to ensure that pressure from external water or soil is exceeded and
    that the pile is neither reduced in section nor contaminated.
    (b) Concrete shall be topped up as necessary while the casing is extracted until the
    required head of concrete to complete the pile in a sound and proper manner has been
    provided. No concrete is to be placed once the bottom of the casing has been lifted
    above the top of the concrete.

    3 Vibrating Extractors

    (a) The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and
    Disturbance) and (Damage to Adjacent Structures).
    QCS 2014 Section 04: Foundations and Retaining Structures Page 27
    Part 04: Deep Foundations

    4 Concrete Casting Tolerances

    (a) For piles constructed without the use of a rigid permanent lining, pile concrete shall be
    cast to the original ground level.
    (b) Where piles are constructed inside rigid permanent lining tubes or permanent casings,
    pile heads shall be cast to a level above the specified cut-off so that, after trimming, a
    sound concrete connection with the pile can be made. In this case, the tolerance of
    casting above the cut-off level shall be determined according to Table 4.6.

    Table 4.6

    Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining
    Tubes or Permanent Casings

    Cut-off distance below original Casting tolerance above cut-off level

    l .
    ground, H, (m) (m)

    .l.
    rw
    0.15 to any depth 2.2 + H/10

    5
    ta
    Repair of damaged pile heads and making-up of piles to the correct level
    qa
    (a) When repairing or extending the head of a pile, the head shall be cut off square in
    sound concrete, and all loose particles shall be removed by wire brushing, followed by
    washing with water.
    as

    (b) If the driving of a pile has been accepted but sound concrete of the pile is below the
    se

    cut-off level, the pile shall be made good to the cut-off level with concrete of a grade
    not inferior to that of the concrete of the pile.
    er

    6 Lengthening of cast-in- place piles after driving


    ov

    (a) When it is required to extend a cast-in-place driven pile above ground, the materials to
    be used and procedures to be adopted shall be subject to the approval of the
    o

    Engineer.
    it

    7 Lengthening of permanent pile casings during construction


    et

    (a) The lengthening of permanent steel pile casings by adding an additional length of the
    m

    same steel casing during construction shall be carried out in accordance with the
    relevant clauses of this Section or by other approved methods. The use of casing
    extension materials and methods other than those specified shall be subject to
    approval.

    8 Temporary backfilling above pile casting level

    (a) After each pile has been cast, any hole remaining shall be protected and shall be
    carefully backfilled as soon as possible with approved materials.

    9 Cutting off pile heads

    (a) When cutting off and trimming piles to the specified cut-off level, the Contractor shall
    take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked
    or defective concrete shall be cut away and the pile repaired in an approved manner to
    provide a full and sound section to the cut-off level.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 28
    Part 04: Deep Foundations

    4.6 STEEL PILES

    4.6.1 Scope

    1 This Part applies to driven steel piles designed to act as bearing piles.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation.


    Section 5, Concrete

    . l
    4.6.2 References

    .l.
    rw
    1 The following standards and other documents are referred to in this Part:
    BS 4, ..........................Structural steel sections

    ta
    BS 3100, ....................Steel casting for general engineering purposes.
    BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels
    qa
    BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel
    BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates
    as

    API 5L,........................Interpretation of non-destructive testing.


    se

    4.6.3 Submittals
    er

    1 Where coatings are specified, the Contractor shall submit for approval full details of the
    coating procedure and surface preparation according to relevant British or Swedish
    ov

    Standards.
    o

    4.6.4 Quality Assurance


    it
    et

    1 The Contractor shall provide the Engineer with Works test certificates, analyses, and mill
    sheets, together with a tube manufacturer's certificate showing details of the pile number,
    m

    cast number of the steel and a record of all tests and inspections carried out. The Engineer
    has the right to inspect any stage of the manufacturing processes and shall be given
    adequate notice by the Contractor of such processes and production tests, provided that,
    once he has been notified, any delay in his attendance does not cause delay to, or disrupt,
    the manufacturing process. The Contractor shall provide the Engineer with samples for
    independent testing when requested.

    2 The Contractor shall submit for approval full details of the welding procedures and
    electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as
    may be required by the relevant British Standard or as may be required by the Engineer.
    Only welders who are qualified in the approved welding procedure in accordance with the
    tests laid down in the relevant British Standard, or who have a proven record over the
    previous six months, or who have attained a similar standard, shall be employed on the
    Works. Proof of welders' proficiency shall be made available to the Engineer on request.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 29
    Part 04: Deep Foundations

    4.6.5 Delivery, Storage and Handling

    1 The Contractor shall

    (a) Order the piles to suit the construction programme.


    (b) Obtain the Engineer's approval before placing the order.

    2 When preliminary piles are specified, the approval for the piles for the main work will not
    necessarily be given until the results of the driving and tests on preliminary piles have been
    received and evaluated.

    3 Each pile shall be clearly numbered and its length shown near the pile head using white
    paint. In addition, before being driven, each pile shall be graduated at appropriate intervals
    along its length and at intervals of 250 mm along the top 3 m.

    l.
    4 All piles within a stack shall be in groups of the same length and on approved supports. All

    .l.
    operations such as handling, transporting and storing of piles shall be carried out in a manner

    rw
    such that damage to piles and their coatings is minimised.

    4.6.6 Materials

    1 Pile Shoes ta
    qa
    (a) Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded
    fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related
    as

    standards.
    se

    2 Strengthening of Piles
    er

    (a) The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head
    of a pile shall be made using material of the same grade as the pile unless otherwise
    ov

    approved.

    3 Manufacturing Tolerance
    it o

    (a) All piles shall be of the type and cross-sectional dimensions specified. For standard
    et

    rolled sections the dimensional tolerances and weight shall comply with the relevant
    standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified.
    m

    For proprietary sections the dimensional tolerances shall comply with the
    manufacturer's standards. The rolling or manufacturing tolerances for proprietary
    sections shall be such that the actual weight of section does not differ from the
    theoretical weight by more than +4 % or -2 % unless otherwise agreed. The rolling
    or manufacturing tolerances for steel tubular piles shall be such that the actual weight
    of section does not differ from the theoretical weight by more than 5 %.

    4 Straightness of Piles

    (a) For standard rolled sections the deviation from straightness shall be within the
    compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by
    butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall
    length of the pile.
    (b) For proprietary sections made up from rolled sections, and for tubular piles, the
    deviation from straightness on any longitudinal face shall not exceed 1/600 of the
    length of the pile nor 5 mm in any 3 m length.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 30
    Part 04: Deep Foundations

    5 Fabrication of Piles

    (a) For tubular piles where the load will be carried by the wall of the pile, and if the pile will
    be subject to loads that induce reversal of stress during or after construction, the
    external diameter at any section as measured by using a steel tape on the
    circumference shall not differ from the theoretical diameter by more than 1.
    (b) The ends of all tubular piles as manufactured shall be within a tolerance on ovality of
    1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile
    length.
    (c) The root edges or root faces of lengths of piles that are to be shop butt-welded shall
    not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick
    or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of
    unequal wall thickness are to be butt-welded, the thickness of the thinner material shall
    be the criterion.

    l .
    .l.
    6 Matching of Pile Lengths

    rw
    (a) Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being
    joined shall, whenever possible, be evenly staggered at the butt. However, if in order
    to obtain a satisfactory match of the ends of piles or to meet specified straightness, the
    ta
    seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.
    qa
    7 Welding
    as

    (a) Welding of H-piles and piles that will be subjected to stress reversal, during or after
    construction, shall be in accordance with BS 5135.
    se

    (b) For a tubular pile where the load will be compressive and non-reversible and will be
    carried by the wall of the pile or by composite action with a concrete core, the welding
    er

    shall be to BS 5135 or BS 6265.


    ov

    8 Coating Piles for Protection against Corrosion

    (a) Where coatings are specified they shall be provided in accordance with the Particular
    o

    Specification. In general, coatings will not be called for where piles are fully in contact
    it

    with undisturbed natural soils or below the standing water table. Cathodic protection
    et

    may be called for when there is a possibility of stray electrical current from the
    supported structure flowing to earth through the piles.
    m

    4.6.7 Acceptance Standards For Welds

    1 Acceptance Standards for Shop Welds

    (a) Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the
    acceptance standard for interpretation of non-destructive testing specified in latest
    edition of API 5L. The maximum projecting height of weld reinforcement shall not
    exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall
    thicknesses greater than 13 mm.
    (b) Longitudinal welds joining the constituent parts of the box or proprietary section shall
    be in accordance with the manufacturer's specification.
    (c) The maximum projecting height of weld reinforcement for circumferential welds in
    tubular piles shall be the same as specified above for longitudinal welds in tubular
    piles.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 31
    Part 04: Deep Foundations

    2 Acceptance Standards for Site Butt Welds

    (a) Welds shall comply with the requirements of the Weld Quality Acceptance Standards
    for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation,
    General Steels Group.

    4.6.8 Acceptability and inspection of coatings

    1 The finished coating shall be generally of smooth and uniform texture and free from sharp
    protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

    2 Any coat damaged by subsequent processes, or which has deteriorated to an extent such
    that proper adhesion of the coating is in doubt, shall be removed and the surface shall be
    cleaned to the original standard and recoated with the specified number and thicknesses of
    coats.

    l .
    .l.
    3 The completed coating shall be checked for thickness by an approved magnetic thickness
    gauge. Areas where the thickness is less than that specified shall receive approved

    rw
    additional coating.

    4
    ta
    Average measured thickness should be equal to or greater than the specified thickness and
    no single reading should be less than 85 % of the specified thickness. The completed
    qa
    coating shall also be checked for adhesion by the cross-hatching method with lines spaced at
    ten times the thickness of the coating. Adhesion tests should not be carried out prior to
    seven days after coating.
    as

    5 The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved
    se

    shall be sand blasted and recoated. The coating shall be approved before pitching and
    driving of the piles.
    er

    4.6.9 Driving of piles


    ov

    1 Leaders and Trestles


    o

    (a) At all stages during driving and until incorporation in the superstructure, the free length
    it

    of the pile shall be adequately supported and restrained by means of leaders, trestles,
    et

    temporary supports or other guide arrangements to maintain position and alignment


    m

    and to prevent buckling. In marine works, lengths which remain unsupported after
    driving shall be adequately restrained until incorporated into the permanent Works.
    These constraint arrangements shall be such that damage to piles and their coatings is
    minimised.

    2 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment. Where required in the Contract, dynamic evaluation
    and analysis shall be provided.
    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile unless otherwise approved by the Engineer. For other types of hammer the
    energy delivered to the pile per blow shall be at least equivalent to that of a drop
    hammer of the stated mass. Drop hammers shall not be used from floating craft in
    such a manner as to cause instability of the craft.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 32
    Part 04: Deep Foundations

    3 Length of Piles

    (a) The length of pile to be driven and any additional lengths of pile to be added during
    driving shall be approved by the Engineer.

    4 Driving Procedure and Redrive Checks

    (a) The driving of each pile shall be continuous until the specified depth or resistance
    (set), or both, has been reached. In the event of unavoidable interruption to driving,
    the pile will be accepted provided it can be driven to the specified depth or resistance
    (set), or both, without damage.
    (b) A follower shall not be used unless approved, in which case the Engineer will require
    the set where applicable to be revised in order to take into account reduction in the
    effectiveness of the hammer blow.

    .
    (c) The Contractor shall inform the Engineer as soon as an unexpected change in driving

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    characteristics is noted. A detailed record of the driving resistance over the full length
    of the nearest subsequent pile shall be taken, if required by the Engineer.

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    (d) At the start of the work in a new area or section a detailed record shall be made over
    the full driving length of the first pile, and during the last 3 m of the driving of

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    subsequent piles, to establish the driving behaviour. Where required, detailed driving
    records shall also be made for 5 % of the piles driven, the locations of such piles being
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    specified by the Engineer.
    (e) The Contractor shall give adequate notice and provide all necessary facilities to enable
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    the Engineer to check driving resistance. A set or resistance measurement shall be


    taken only in the presence of the Engineer unless otherwise approved.
    se

    (f) Redrive checks, if required, shall be carried out in accordance with an approved
    procedure.
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    5 Final Set or Resistance


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    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
    penetration in millimetres per ten blows or as the number of blows required to produce
    o

    a penetration of 25 mm.
    it
    et

    (b) When a final set or resistance is being measured, the following requirements shall be
    met:
    m

    (i) The exposed part of the pile shall be in good condition, without damage or
    distortion.
    (ii) The dolly and packing, if any, shall be in sound condition.
    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    be flat and at right angles to the pile and hammer axis.
    (iv) The hammer shall be in good condition, delivering adequate energy per blow
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded, if required by the
    Engineer.

    6 Preboring

    (a) If preboring is specified the pile shall be pitched after preboring to the designated
    depth and diameter.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 33
    Part 04: Deep Foundations

    7 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.

    4.6.10 Risen Piles

    1 Piles shall be driven in an approved sequence to minimise any detrimental effects of heave
    and lateral displacement of the ground.

    2 When required by the Engineer, levels and measurements shall be taken to determine the
    movement of the ground or any pile resulting from the driving of adjacent piles.

    3 When a pile has risen as a result of adjacent piles being driven, the Engineer may call for
    redriving or other testing to demonstrate that the performance of the pile under load is

    .
    unimpaired. If required, the Contractor shall make proposals for correcting detrimentally

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    affected piles and for avoidance or control of heave in subsequent work.

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    4.6.11 Preparation of pile heads

    1
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    If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within
    5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete
    qa
    they shall be cut to that same tolerance and protective coatings shall be removed from the
    surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.
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    4.7 MICROPILES (TO BE ADDED LATER)


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    4.8 REDUCTION OF FRICTION ON PILES


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    4.8.1 Scope
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    1 This Part includes preapplied bituminous or other proprietary friction-reducing coating, pre-
    applied low-friction sleeving, formed-in-place low-friction surround, and preinstalled low-
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    friction sleeving.
    it
    et

    2 Related Parts are as follows:


    m

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 3, Ground Investigation.
    4.8.2 Submittals

    1 Where the particular method of reducing friction is not specified, the Contractor shall submit
    full details of the method which he proposes.

    4.8.3 Friction Reducing Methods

    1 General

    (a) Where a means of reducing friction on any specified length of pile is required by the
    Contract, the Contractor shall provide a suitable interface between pile and soil by one
    of the following, or other approved, methods
    QCS 2014 Section 04: Foundations and Retaining Structures Page 34
    Part 04: Deep Foundations

    (i) Preapplied bituminous or other proprietary friction-reducing coating.


    (ii) Preapplied low-friction sleeving.
    (iii) Formed-in-place low-friction surrounds.
    (iv) Preinstalled low-friction sleeving.

    2 Preapplied Bituminous or other Friction-Reducing Coating Materials

    (a) Where a proprietary product is specified, the process of cleaning pile surfaces, and the
    conditions and methods of application shall conform to the manufacturer's current
    instructions. All materials shall conform to the manufacturer's specification, which
    shall be given to the Engineer before any coating is applied.
    (b) Where a friction-reducing material has been applied to a preformed pile prior to
    installation, it shall be protected from damage during handling and transportation. In

    .
    the event of inadvertent damage to the coating, it shall be repaired on site, prior to the

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    .l.
    pile being driven, to the same specification as the original coating. Where bituminous
    materials are involved, precautions shall be taken as necessary in hot weather to

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    prevent excessive flow or displacement of the coating. The coated piles shall be
    adequately protected against direct sunlight and, if stacked, they shall be separated to
    prevent their coatings sticking together.
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    qa
    (c) In the case of applied coatings, the piles shall not be driven when the air temperature
    is such that the coating will crack, flake or otherwise be damaged prior to entry into the
    ground. Where bituminous materials are involved, driving shall be carried out while
    as

    the temperature is at or above 5 C unless otherwise approved or called for in the


    manufacturer's instructions.
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    3 Preapplied Low-Friction Sleeving


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    (a) Piles may be driven with a preapplied low-friction sleeving subject to the approval of
    the detailed design and method by the Engineer.
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    4 Formed-In-Place Low-Friction Surround


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    (a) Where a hole is bored in the ground and filled with low-friction material through which a
    it

    pile is subsequently driven or placed, the method and the properties of the low-friction
    et

    material both above and below standing groundwater level, together with the
    dimensions of the prebored hole in relation to the pile, shall be approved by the
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    Engineer.

    5 Preinstalled Low-Friction Sleeving

    (a) Where a system is employed involving placing a low-friction sleeve in the ground prior
    to pile installation, the detailed materials and method of installation of the sleeving shall
    be approved by the Engineer.

    4.8.4 Inspection

    1 The Engineer may call for piles to be partially exposed or extracted at the commencement of
    a contract in order to demonstrate that the method of installation does not impair the
    effectiveness of the system in the circumstances of use on the particular site. Where damage
    is found to have occurred, or is likely to occur in the opinion of the Engineer, additional
    measures or variation of the method may be called for. At the discretion of the Engineer,
    further inspections shall be carried out to ascertain the effectiveness of the additional
    measures.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 35
    Part 04: Deep Foundations

    4.8.5 Driving resistance

    1 Allowance shall be made in driving piles to a required resistance or set for any differences
    between the short-term driving resistance and the long-term static resistance of the coating
    or surrounding low-friction material which is in use.

    4.9 PILE LOAD TESTING

    4.9.1 Static Load Testing of Piles

    1 Scope

    (a) This Part deals with the testing of a pile by the controlled application of an axial load. It
    covers vertical and raking piles tested in compression (i.e. subjected to loads or forces
    in a direction such as would cause the piles to penetrate further into the ground) and

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    vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as

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    would cause the piles to be extracted from the ground).

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    2 References

    The following standard is referred to in this Part:


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    BS 1881, ....................Methods of testing concrete.
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    3 Submittals
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    (a) When required, the design and full details of the proposed load application system
    shall be submitted to the Engineer prior to the commencement of testing. The load
    se

    application system shall be satisfactory for the required test.

    4 Definitions
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    (a) Allowable pile capacity: a load which is not less than the specified working load and
    ov

    which takes into account the pile's ultimate bearing capacity, the materials from which
    the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the
    o

    overall bearing capacity of the ground beneath the piles and any other relevant factors.
    it

    The allowable pile capacity indicates the ability of a pile to meet the specified loading
    et

    requirements.
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    (b) Compression pile: a pile which is designed to resist compressive (downward) axial
    load.
    (c) Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate
    the soil at a constant controlled speed, while the loads applied at the top of the pile in
    order to maintain the constant rate of penetration are continuously measured. The
    purpose of the test is to derive the ultimate bearing capacity of a pile and not its load
    settlement characteristics.
    (d) Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is
    subject to tension rather than compression. The purpose of the test is to determine
    the 'pull-out' capacity of a pile.
    (e) Design verification load (DVL): a test load, in lieu of a specified working load, applied
    to a single pile at the time of testing to determine that site conditions conform to design
    assumptions. This load will be peculiar to each preliminary (test) pile and should equal
    the maximum specified working load for a pile of the same dimensions and material,
    plus allowances for soil-induced forces and any other particular conditions of the test.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 36
    Part 04: Deep Foundations

    (f) Kentledge: ballast used in a loading test.


    (g) Maintained load test: a loading test in which each increment of load is held constant
    either for a defined period of time or until the rate of settlement falls to a specified
    value.
    (h) Preliminary pile: a test pile installed before the commencement of the main piling
    works or a specific part of the Works for the purpose of establishing the suitability of
    the chosen type of pile and for confirming its design, dimensions and bearing capacity.
    (i) Proof load: a load applied to a selected working pile to confirm that it is suitable for the
    load at the settlement specified. A proof load should not normally exceed the design
    verification load plus 50 % of the specified working load.
    (j) Raking pile: a batter pile, installed at an inclination to the vertical.
    (k) Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a

    .
    resistance against which the pile is tested.

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    .l.
    (l) Specified working load (SWL): the designated load on the head of a pile.

    rw
    (m) Tension pile: a pile which is designed to resist a tensile (upward) axial force.
    (n) Test pile: any pile, preliminary or part of the works, to which a test is applied.
    (o) ta
    Ultimate bearing capacity: the load at which the resistance of the soil becomes fully
    qa
    mobilised through friction, end bearing or a combination thereof.
    (p) Working pile: one of the piles forming the foundation of a structure.
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    5 Construction of a preliminary pile to be tested


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    (a) Notice of Construction


    (i) The Contractor shall give the Engineer at least 48 hours' notice of the
    er

    commencement of construction of any preliminary pile which is to be test-


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    loaded.
    (b) Method of Construction
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    (i) Each preliminary test pile shall be constructed in a manner similar to that to be
    it

    used for the construction of the working piles, and by the use of similar
    et

    equipment and materials. Any variation will be permitted only with prior approval.
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    (c) Boring or Driving Record


    (i) For each preliminary pile to be tested, a detailed record of the conditions
    experienced during boring and of the progress during driving, shall be made and
    submitted to the Engineer daily, not later than noon on the next working day.
    Where the Engineer requires soil samples to be taken or in-situ tests to be
    made, the Contractor shall include that in the daily report, as well as the test
    results.
    (d) Concrete Test Cubes
    (i) In the case of concrete piles, four test cubes shall be made from the concrete
    3
    used in the manufacturer of each preliminary test pile and from each 50 m of
    the concrete used in the manufacture of working piles. If a concrete pile is
    extended or capped for the purpose of testing, an additional four cubes shall be
    made from the corresponding batch of concrete. The cubes shall be made and
    tested in accordance with BS 1881.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 37
    Part 04: Deep Foundations

    (ii) The pile test shall not be started until the strength of the cubes taken from the
    pile exceeds twice the average direct stress in any pile section under the
    maximum required test load, and the strength of the cubes taken from the cap
    exceeds twice the average stress at any point in the cap under the same load.
    Variation of procedure will be permitted only if approved by the Engineer.
    (e) Preparation of a Working Pile to be Tested
    (i) If a test is required on a working pile the Contractor shall cut off or otherwise
    prepare the pile for testing as required by the Engineer.
    (f) Cut-off Level
    (i) The cut-off level for a preliminary test pile shall be approved by the Engineer.

    6 Supervision

    .
    (a) The setting-up of pile testing equipment shall be carried out under competent

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    supervision and the equipment shall be checked to ensure that the set-up is
    satisfactory before the commencement of load application.

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    (b) All tests shall be carried out only under the direction of an experienced and competent
    supervisor experienced with the test equipment and test procedure. All personnel

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    operating the test equipment shall have been trained in its use.
    qa
    7 Safety precautions

    (a) General
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    (i) Design, erection and dismantling of the pile test reaction system and the
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    application of load shall be carried out according to the requirements of the


    various applicable statutory regulations concerned with lifting and handling
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    heavy equipment and shall safeguard operators and others who may from time
    to time be in the vicinity of a test from all avoidable hazards.
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    (b) Kentledge
    (i) Where kentledge is used, the Contractor shall construct the foundations for the
    o

    kentledge and any cribwork, beams or other supporting structure in such a


    it

    manner that there will not be differential settlement, bending or deflexion of an


    et

    amount that constitutes a hazard to safety or impairs the efficiency of the


    operation. The kentledge shall be adequately bonded, tied or otherwise held
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    together to prevent it becoming unstable because of deflexion of the supports or


    for any other reason.
    (ii) When kentledge constitutes the principal component of a reaction system, its
    weight for each test shall be at least 25% greater than the maximum test load
    for that test. The weight may be determined by scale or the density and volume
    of the constituent materials. In adding kentledge, care shall be taken to properly
    position the centre of gravity of the stack.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 38
    Part 04: Deep Foundations

    (c) Tension Piles, Reaction Piles and Ground Anchorages


    (i) Where tension piles, reaction piles or ground anchorages constitute the principal
    components of a reaction system, they shall be so designed that they will resist
    the forces applied to them safely and without excessive deformation which could
    cause a safety hazard during the work. Such piles (which, unless approved, will
    not be working piles) or anchorages shall be driven in the specified locations,
    and all bars, tendons or links shall be aligned to provide a stable reaction in the
    direction required. Any welding employed to extend or to fix anchorages to a
    reaction frame shall be carried out so that the full strength of the system is
    adequate and unimpaired.
    (d) Testing Equipment
    (i) In all cases the Contractor shall ensure that when the hydraulic jack and load-
    measuring device are mounted on the pile head the whole system will be stable

    .
    up to the maximum load to be applied.

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    (ii) If in the course of carrying out a test any unforeseen occurrence should take

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    place, further loading shall not be applied until a proper engineering assessment
    of the condition has been made and steps have been taken to rectify any fault.
    Reading of gauges should, however, be continued where possible and if it is
    safe to do so.
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    (iii) Where an inadequacy in any part of the system might constitute a hazard,
    means shall be provided to enable the test to he controlled from a position
    remote from of the kentledge stack or test frame.
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    (iv) The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
    se

    operated under hydraulic pressure shall be capable of withstanding a pressure


    of 1.5 times the maximum pressure used in the test without leaking. The
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    maximum test load expressed as a reading on the gauge in use shall be


    displayed and all operators shall be made aware of this limit.
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    (e) Pile Head for Compression Test


    (i) For a pile that is tested in compression, the pile head or cap shall be formed to
    o

    give a plane surface which is normal to the axis of the pile, sufficiently large to
    it

    accommodate the loading and settlement measuring equipment and adequately


    et

    reinforced or protected to prevent damage from the concentrated load applied


    m

    by the loading equipment.


    (ii) Any test pile cap shall be concentric with the test pile; the joint between the cap
    and the pile shall have a strength equivalent to that of the pile.
    (iii) Sufficient clear space shall be made under any part of the cap projecting beyond
    the section of the pile so that, at the maximum expected settlement, load is not
    transmitted to the ground by the cap.
    (f) Pile Connection for Tension Test
    (i) For a pile that is tested in tension, means shall be provided for transmitting the
    test load axially without inducing moment in the pile. The connection between
    the pile and the loading equipment shall be constructed in such a manner as to
    provide strength equal to 1.5 times the maximum load which is to be applied to
    the pile during the test.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 39
    Part 04: Deep Foundations

    8 Reaction systems

    (a) Compression Tests


    (i) The reaction for compression tests shall be provided by kentledge, tension piles
    or specially constructed anchorages. Kentledge shall not be used for tests on
    raking piles except where the test set-up has been specifically designed to
    conform to Item 7(g). and has been approved by the Engineer.
    (ii) Where kentledge is to be used, it shall be supported on cribwork and positioned
    so that the centre of gravity of the load is as close as possible to the axis of the
    pile. The bearing pressure under supporting cribs shall be such as to ensure
    stability of the kentledge stack.
    (b) Tension Tests
    (i) The reaction for tension tests shall be provided by compression piles, rafts or

    l .
    grillages constructed on the ground. In all cases the resultant force of the

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    reaction system shall be coaxial with the test pile.

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    (ii) Where inclined piles or reactions are proposed, full details shall be submitted for
    approval prior to the commencement of testing.
    (c) Working Piles
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    qa
    (i) Working piles shall not be used as reaction piles without approval from the
    Engineer.
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    (ii) Where working piles are used as reaction piles their movement shall be
    measured and recorded to with an accuracy of 0.5 mm, and recorded.
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    (d) Spacing
    (i) Where kentledge is used for loading vertical piles in compression, the distance
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    from the edge of the test pile to the nearest part of the crib supporting the
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    kentledge stack in contact with the ground shall be not less than 1.3 m.
    (ii) The centre-to-centre spacing of vertical reaction piles from a test pile shall
    conform to Paragraph 1 above, but shall be not less than three times the
    o

    diameter of the test pile or the reaction piles or 2 m, whichever is the greatest,
    it

    except in the case of piles of 300 mm diameter (or equivalent) or less, where the
    et

    distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged


    m

    pile cap, the same criterion shall apply with regard to the pile shaft, with the
    additional requirement that no surface of a reaction pile shall be closer to the
    pile cap of the test pile than one half of the pile cap plan dimension.
    (iii) Where ground anchorages are used to provide a test reaction for loading in
    compression, no section of fixed anchor length transferring load to the ground
    shall be closer to the test pile than three times the diameter of the test pile.
    Where the pile to be tested has an enlarged pile cap, the same criterion shall
    apply with regard to the pile shaft, with the additional requirement that no section
    of the fixed anchor transferring load to the ground shall be closer to the pile cap
    than a distance equal to one half the pile cap plan dimension.
    (e) Adequate Reaction
    (i) The reaction frame support system shall be adequate to transmit the maximum
    test load in a safe manner without excessive movement or influence on the test
    pile. Calculations shall be provided to the Engineer when required to justify the
    design of the reaction system.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 40
    Part 04: Deep Foundations

    (f) Care of Piles


    (i) The method employed in the installation of the reaction system shall be such as
    to prevent damage to any test pile or working pile.

    9 Equipment for applying load

    (a) The equipment used for applying load shall consist of a hydraulic ram or jack. The
    jack shall be arranged in conjunction with the reaction system to deliver an axial load
    to the test pile. Proposals to use more than one ram or jack will be subject to approval
    by the Engineer of the detailed arrangement. The complete system shall be capable of
    safely transferring the maximum load required for the test. The length of stroke of a
    ram shall be sufficient to account for deflexion of the reaction system under load plus a
    deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise
    specified or agreed prior to commencement of test loading.

    l .
    10 Measurement of load

    .l.
    (a) A load measuring device shall be used and in addition a calibrated pressure gauge

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    included in the hydraulic system. Readings of both the load measuring device and the
    pressure gauge shall be recorded. In interpreting the test data the values given by the

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    load measuring device shall normally be used; the pressure gauge readings are
    required as a check for gross error.
    qa
    (b) The load measuring device may consist of a load measuring column, pressure cell or
    other appropriate system. A spherical seating of appropriate size shall he used to
    as

    avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load
    application and measuring system. Load measuring and application devices shall be
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    short in axial length in order to secure stability. The Contractor shall ensure that axial
    loading is maintained.
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    (c) The load measuring device shall be calibrated before and after each series of tests,
    whenever adjustments are made to the device or at intervals appropriate to the type of
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    equipment. The pressure gauge and hydraulic jack shall be calibrated together.
    Certificates of calibration shall be supplied to the Engineer.
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    11 Control of loading
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    et

    (a) The loading equipment shall enable the load to be increased or decreased smoothly or
    m

    to be held constant at any required value.

    12 Measuring pile head movement

    (a) Maintained Load Test


    (i) In a maintained load test, movement of the pile head shall he measured by one
    of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one
    of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.
    (b) CRP and CRU Tests
    (i) In a CRP or a CRU test, the method in Item 11 (d) shall be used. Check-
    levelling of the reference frame or the pile head shall not be required. The dial
    gauge shall be graduated in divisions of 0.02 mm or less.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 41
    Part 04: Deep Foundations

    (c) Reference Beams and Dial Gauges


    (i) An independent reference beam or beams shall be set up to enable
    measurement of the movement of the pile to be made to the required accuracy.
    The supports for a beam shall be founded in such a manner and at such a
    distance from the test pile and reaction system that movements of the ground
    do not cause movement of the reference beam or beams which will affect the
    accuracy of the test. The supports of the beam or beams shall be at least three
    test pile diameters or 2 m from the centre of the test pile, whichever distance is
    the greater.
    (ii) Check observations of any movements of the reference beam or beams shall be
    made and a check shall be made of the movement of the pile head relative to a
    remote reference datum at suitable intervals during the progress of the test.
    (iii) The measurement of pile movement shall be made by four dial gauges rigidly

    .
    mounted on the reference beam or beams, bearing on prepared flat surfaces

    l
    .l.
    fixed to the pile cap or head and normal to the pile axis. Alternatively, the
    gauges may be fixed to the pile and bear on prepared surfaces on the reference

    rw
    beam or beams. The dial gauges shall be placed equidistant from the pile axis
    and from each other. The dial gauges shall enable readings to be made to an

    ta
    accuracy of at least 0.1 mm and have a stem travel of at least 25 mm.
    Machined spacer blocks may be used to extend the range of reading. Equivalent
    qa
    electrical displacement-measuring devices may be substituted.
    (d) Optical Levelling Method
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    (i) An optical levelling method by reference to a remote datum may be used.


    se

    (ii) Where a level and staff are used, the level and scale of the staff shall be chosen
    to enable readings to be made to within an accuracy of 0.5 mm. A scale
    er

    attached to the pile or pile cap may be used instead of a levelling staff. At least
    two reliable independent datum points shall be established. Each datum point
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    shall be so situated as to permit a single setting-up position of the level for all
    readings.
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    (iii) No datum point shall be located where it can be affected by the test loading or
    it

    other operations on the Site.


    et

    (e) Reference Wires and Scales


    m

    (i) Two parallel reference wires, one on either side of the pile, shall be held under
    constant tension at right angles to the test pile axis between supports formed as
    in the method in Item 11 (d). The wires shall be positioned against scales fixed
    to the test pile head in an axial direction and the movements of the scales
    relative to the wires shall be determined.
    (ii) Check observations of any movements of the supports of the wires shall be
    made and a check shall be made on the movement of the pile head at approved
    time intervals. Readings shall be taken to within an accuracy of 0.5 mm.
    (f) Other Methods
    (i) The Contractor may submit for approval any other method of measuring the
    movement of the test pile head.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 42
    Part 04: Deep Foundations

    13 Protection of testing equipment

    (a) Protection from Weather


    (i) Throughout the test period all equipment for measuring load and movement
    shall be protected from exposure to adverse effect of weather.
    (b) Prevention of Disturbance
    (i) Construction activity and persons who are not involved in the testing process
    shall be kept at a sufficient distance from the test to avoid disturbance to the
    measuring apparatus. Full records shall be kept of any intermittent unavoidable
    activity that might affect the test set-up.

    14 Notice of test

    (i) The Contractor shall give the Engineer at least 24 hours' notice of the

    .
    commencement of the test. No load shall be applied to the test pile before the

    l
    .l.
    commencement of the specified test procedure.

    rw
    15 Test procedure

    (a) Proof Load Test Procedure (working compression piles)


    (i) ta
    The maximum load which shall be applied in a proof test shall normally be the
    qa
    sum of the design verification load (DVL) plus 50 % of the specified working load
    (SWL). The loading and unloading shall be carried out in stages as shown in
    Table 4.7. Any particular requirements given in the particular contract
    as

    documentation shall be complied with.


    se

    (ii) Following each application of an increment of load, the load shall be maintained
    at the specified value for not less than the period shown in Table 4.7 and until
    er

    the rate of settlement is less than 0.25 mm/h and decreasing. The rate of
    settlement shall be calculated from the slope of the line obtained by plotting
    ov

    values of settlement versus time and drawing a smooth curve through the
    points.
    o

    (iii) Each decrement of unloading shall proceed after the expiry of the period shown
    it

    in Table 4.7.
    et

    (iv) For any period when the load is constant, time and settlement shall be recorded
    m

    immediately on reaching the load, at not more than 5 min intervals up to 15 min;
    at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and
    4 h; and 1 h intervals between 4 h and 12 h after the application of the increment
    of load.
    (v) Where the methods of measuring pile head movement given in Item 11 is used,
    the periods of time for which loads must be held constant to achieve the
    specified rates of settlement shall be extended as necessary to take into
    account the lower levels of accuracy available from these methods and to allow
    correct assessment of the settlement rate.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 43
    Part 04: Deep Foundations

    Table 4.7
    Load * Minimum time of holding load
    25% DVL 1h
    50% DVL 1h
    75% DVL 1h
    100% DVL 1h
    75% DVL 10 min
    50% DVL 10 min
    25% DVL 10 min
    0 1h
    100% DVL 6h
    100% DVL + 25% SWL 1h
    100% DVL + 50% SWL 6h
    100% DVL + 25% SWL 10 min

    l .
    100% DVL 10 min

    .l.
    75% DVL 10 min

    rw
    50% DVL 10 min
    25% DVL 10 min
    0 1h
    100% DVL
    100% DVL + 50% SWL ta 6h
    6h
    qa
    100% DVL + 75% SWL 1h
    100% DVL + 100% SWL 6h
    100% DVL + 75% SWL 10 min Applicable
    as

    100% DVL + 50% SW 10 min to tests on


    100% DVL + 25% SW 10 min Preliminary
    se

    100% DVL 10 min Pile only


    75% DVL 10 min
    50% DVL 10 min
    er

    25% DVL 10 min


    ov

    0 1h
    * SWL denotes specified working load; DVL denotes design verification load.
    o

    (b) Test Procedure for Preliminary Compression Piles


    it

    (i) The procedure to be adopted for carrying out load tests on preliminary
    et

    compression piles shall be either the extended proof load test procedure or the
    m

    constant rate of penetration testing procedure given below. A normal proof load
    test will constitute the first stage of such a test unless otherwise specified.
    (ii) Extended proof load test procedure. Where test pile is to be loaded up to the
    sum of design verification load (DVL) plus 100 % of the specified working load,
    the loading procedure may be carried out as a continuation of the proof load
    testing procedure given in Item 14 (a).
    (iii) Following the completion of the proof load test, the load shall be restored in two
    stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages
    of 25 % of the specified working load. Following each application of an
    increment of load, the load shall be maintained at the specified value for the
    period shown in Table 4.7 and until the rate of settlement is decreasing and is
    less than 0.25 mm/h.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 44
    Part 04: Deep Foundations

    (iv) Where verification of required minimum factor of safety is called for or the pile is
    to be tested to failure, the loading procedure shall be continued after reaching
    DVL +100 % SWL stage by increasing the load in increments of 25 % of the
    specified working load or other specified amount until the maximum specified
    load of the test is reached. Following each application of increment of load, the
    load shall be maintained at the specified value for not less than 1 h and until the
    rate of settlement is decreasing and is less than 0.25 mm/h, or other approved
    rate appropriate to the stage of loading and its proximity to a failure condition.
    Permissible settlement at the load corresponding to the required minimum factor
    of safety called for in the design will not normally be specified.
    (v) The rate of settlement shall be calculated from the slope of the line obtained by
    plotting values of settlement versus time and drawing a smooth curve through
    the points. Reduction of load at the end of the test shall be gradual as required
    by Item 14 (a).and the final rebound of the pile head shall be recorded.

    l .
    (vi) Constant rate of penetration (CRP) testing procedure. Where it is required to

    .l.
    determine the ultimate load of a preliminary compression pile, and particularly

    rw
    where piles are largely embedded in and bearing on clay soils, the CRP testing
    procedure will normally be specified.
    (vii)
    ta
    The rate of movement of the pile head shall be maintained constant in so far as
    is practicable and shall be approximately 0.01 mm/s.
    qa
    (viii) Readings of loads, penetration and time shall be made simultaneously at regular
    intervals; the interval chosen shall be such that a curve of load versus
    as

    penetration can be plotted without ambiguity.


    (ix) Loading shall be continued until one of the following results is obtained
    se

    1. The maximum required test load.


    er

    2. A constant or reducing load has been recorded for an interval of


    ov

    penetration of 10 mm.
    3. A total movement of the pile base equal to 10 % of the base diameter, or
    any other greater value of movement specified, has been reached.
    it o

    (x) The load shall then be reduced in five approximately equal stages to zero load,
    et

    penetration and load being recorded at each stage.


    m

    (c) Testing of Piles Designed to Carry Load in Tension


    (i) The testing of piles designed to carry load in tension shall follow the same
    procedure as specified in 4.9.1
    (ii) In testing by the constant rate of uplift method, overall movements of the pile
    head will normally be less than those expected in a constant rate of penetration
    test. The rate of movement of the pile head shall be maintained at approximately
    0.005 mm/s in so far as is practicable.

    16 Completion of a test

    (a) Removal of Test Equipment


    QCS 2014 Section 04: Foundations and Retaining Structures Page 45
    Part 04: Deep Foundations

    (i) On completion of a test and subject to the approval of the Engineer, all
    measuring equipment and load application devices shall be dismantled and
    checked. All other test equipment, including kentledge, beams and supporting
    structures shall be removed from the test pile location. Measuring and other
    demountable equipment shall be stored in a safe manner so that it is available
    for further tests, or removed from the Site as approved by the Engineer.
    (ii) Temporary tension piles and ground anchorages shall be cut off below ground
    level, and off-cut materials removed from the Site. The ground shall be restored
    to the original contours.
    (b) Preliminary Test Pile Cap
    (i) Unless otherwise specified, the head of each preliminary test pile shall be cut off
    below ground level, off-cut material shall be removed from the Site and the
    ground restored to the original contours.

    l .
    (c) Proof Test Pile Cap

    .l.
    (i) On completion of a test on a proof pile, the test pile cap shall be prepared as

    rw
    specified and left in a state ready for incorporation into the Permanent Works.
    Any resulting off-cut materials shall be removed from the Site.

    4.9.2 Presentation of results


    ta
    qa
    1 Results to be submitted
    as

    (a) During the progress of a test, all records taken shall be available for inspection by the
    Engineer.
    se

    (b) Results shall be submitted as


    er

    (i) Preliminary report of the test results to the Engineer, unless otherwise directed,
    within 24 hours of the completion of the test, which shall show.
    ov

    1. For a test by maintained load: for each stage of loading, the period for
    which the load was held, the load and the maximum pile movement at the
    o

    end of the stage.


    it

    2. For a CRP or CRU test: the maximum load reached and a graph of load
    et

    against penetration or load against uplift.


    m

    (ii) The final report of recorded data as prescribed in Item 15 (b).within ten days of
    the completion of the test.

    2 Schedule of Recorded Data

    (a) The Contractor shall provide information about the test pile in accordance with the
    following schedule where applicable.
    (i) General.
    1. site location contract identification
    2. proposed structure
    3. main contractor
    4. piling contractor
    5. engineer client/employer
    6. date and time of test
    QCS 2014 Section 04: Foundations and Retaining Structures Page 46
    Part 04: Deep Foundations

    (ii) Pile details.


    1. all types of pile
    2. identification (number and location)
    3. specified working load (SWL)
    4. design verification load (DVL)
    5. original ground level at pile location
    6. head level at which test load was applied
    7. type of pile
    8. vertical or raking, compression or tension
    9. shape and size of cross-section of pile, and position of any change in

    .
    cross-section

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    .l.
    10. shoe or base details

    rw
    11. head details
    12. length in ground
    13. tip Elevation
    ta
    qa
    14. dimensions of any permanent casing
    15. concrete piles
    as

    concrete mix/grade

    se

    aggregate type and source


    cement type and cement replacement and type where used
    er

    admixtures
    ov

    slump
    cube test results for pile and cap
    o

    date of casting of precast pile


    it


    et

    reinforcement

    16. steel piles


    m

    steel quality
    coating
    filling or core materials type and quality, if applicable

    (iii) Installation details.


    1. all piles
    dates and times of boring, driving and concreting of test pile
    difficulties and delays encountered
    date and time of casting concrete pile cap

    2. bored piles
    type of equipment used and method of boring
    temporary casing - diameter, type and length
    QCS 2014 Section 04: Foundations and Retaining Structures Page 47
    Part 04: Deep Foundations

    full log of pile borehole


    method of placing concrete
    Volume of concrete placed
    driven preformed and driven cast-in-place piles
    Method of support of hammer and pile driven length of pile or
    temporary casing at final set
    Hammer type, and size or weight
    Dolly and packing, type and condition
    Driving log (depth, hammer drop, blows per 250 mm,
    interruptions or breaks in driving)
    Final set in number of blows to produce penetration of 25 mm

    .
    Redrive check, time interval and set in number of blows to

    l
    .l.
    produce penetration of 25 mm or other agreed amount at final
    set and at redrive set, for a drop hammer or for a single acting

    rw
    hammer the length of the drop or stroke, for a diesel hammer
    the length of the stroke and the blows per minute, for a double
    acting hammer the operating pressure and the number of blows
    per minute
    ta
    qa
    condition of pile head or temporary casing after driving
    use of a follower
    as

    use of preboring
    use of jetting
    se

    lengthening
    er

    method of placing concrete


    ov

    (iv) Test procedure.


    1. mass of kentledge
    o

    2. tension pile, ground anchorage or compression pile details


    it

    3. plan of test arrangement showing position and distances of kentledge


    et

    supports, rafts, tension or compression piles or ground anchorages, and


    m

    supports to pile movement reference system


    4. jack capacity
    5. method of load measurement
    6. method(s) of penetration or uplift measurement
    (v) Test results.
    1. in tabular form
    2. in graphical form: load plotted against pile head movement
    3. ambient temperature records during test.

    4.9.3 Low strain Integrity test

    1 This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in
    Section 2
    QCS 2014 Section 04: Foundations and Retaining Structures Page 48
    Part 04: Deep Foundations

    4.9.4 Grosshole Sonic Logging Test

    1 This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as
    mentioned in Section 2

    4.9.5 Calliper Logging Test

    1 This test shall be carried out in accordance with ASTM D6167 in a frequency as mentioned in
    Section 2

    4.9.6 Axial Tensile Load Test

    1 This test shall be carried out in accordance with ASTM D3689 in a frequency as mentioned in
    Section 2

    l .
    4.9.7 Lateral Load Test

    .l.
    rw
    1 This test shall be carried out in accordance with ASTM D3966 in a frequency as mentioned in
    Section 2

    4.9.8 Alternative Methods for Testing Piles


    ta
    qa
    1 Scope

    (a) This Part outlines the alternative methods for testing piles. A significant advance in
    as

    identifying the existence of defects in construction of piles has been the development
    and adoption of modern integrity testing systems which may be employed to check the
    se

    quality of construction when required by the Engineer.


    er

    (b) Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance
    distribution, and immediate settlement characteristics, hammer transfer energy
    ov

    (efficiency), and pile stresses during driving. The results obtained relate directly to
    dynamic loading conditions.
    o

    (c) Related Sections and Parts are as follows:


    it

    This Section
    et
    m

    Section 2

    2 Quality Assurance

    (a) The testing shall be carried out by an approved firm.


    (b) The interpretation of tests shall be carried out by persons competent in the test
    procedure, and the full test results and findings shall normally be given to the Engineer
    within 10 d of the completion of each phase of testing. Full details of the ground
    conditions, pile dimensions and construction method shall be made available to the
    specialist firm when required in order to facilitate interpretation of the tests.

    3 Integrity-testing of piles

    (a) General
    QCS 2014 Section 04: Foundations and Retaining Structures Page 49
    Part 04: Deep Foundations

    (i) Integrity-testing of piles is designed to give information about the physical


    dimensions, continuity and consistency of materials used in piles, and not to
    give direct information about the performance of piles under the conditions of
    loading. The methods available are normally applied to preformed concrete piles
    made in a single length, to steel piles and to cast-in-place concrete piles.
    (ii) This type of testing will not be regarded as a replacement for static load testing,
    but as a source of supplementary information.
    (iii) There is normally a limit to the length: diameter ratio of pile which can be
    successfully and fully investigated in this way, depending on the ground
    conditions.
    (iv) In the event that any anomaly is found in the results of such testing, the
    Engineer may call for further testing to be carried out in order to investigate the
    cause, nature and extent of the anomaly and whether the pile is satisfactory for

    .
    its intended use.

    l
    .l.
    (b) Method of Testing

    rw
    (i) Where integrity-testing is called for but the method is not specified, the method
    to be adopted shall be approved by the Engineer and shall be one of the
    following
    ta
    qa
    1. The sonic method.
    2. The vibration method.
    as

    3. The sonic logging method.


    (ii) Other methods may be adopted subject to the approval of the Engineer and
    se

    subject to satisfactory evidence of performance.


    er

    (c) Age of Piles at Time of Testing


    (i) In the case of cast-in-place concrete piles, integrity tests shall not be carried out
    ov

    until 7 d or more have elapsed after pile-casting, unless otherwise approved by


    the Engineer.
    o

    (d) Preparation of Pile Heads


    it
    et

    (i) Where the method of testing requires the positioning of sensing equipment on
    the pile head, the head shall be clean, free from water, laitance and loose
    m

    concrete and readily accessible for the purpose of testing.

    4 Dynamic pile-testing

    (a) General
    (i) Dynamic pile-testing involves monitoring the response of a pile to a heavy
    impact applied at the pile head. The impact is often provided by the pile-driving
    hammer and response is normally measured in terms of force and acceleration
    or displacement close to the pile head.
    (ii) The results directly obtained refer to dynamic loading conditions. Interpretation
    in terms of static loading requires soil- and pile-dependent adjustments, and
    corroboration from experience may be required to correlate dynamic testing with
    normal static load tests as specified in clause 4.9.1 of this Section.
    (iii) Details of the equipment to be used and of the method of analysis of test results
    shall be provided to the Engineer before the commencement of testing.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 50
    Part 04: Deep Foundations

    (b) Measuring Instruments


    (i) All instruments affixed to the pile for the purpose of measuring stress and
    movement, and all equipment for receiving and processing data shall be suitable
    for the purpose. The equipment required to be attached to the pile shall be
    appropriately positioned and fixed to the approval of the Engineer.
    (c) Hammer
    (i) The hammer and all other equipment used shall be capable of delivering an
    impact force sufficient to mobilise the equivalent specified test load without
    damaging the pile.
    (d) Preparation of the Pile Head
    (i) The preparation of the pile head for the application of the dynamic test load shall
    involve, where appropriate, trimming the head, cleaning and building up the pile

    .
    using materials which will at the time of testing safely withstand the impact

    l
    .l.
    stresses. The impact surface shall be flat and normal to the axis of the pile.

    rw
    (e) Time of Testing
    (i) Dynamic load tests shall be carried out at appropriate and approved times after

    ta
    pile installation. The time between the completion of installation and testing for
    a preformed pile shall normally be more than 12 h, and in the case of a cast-in-
    qa
    place concrete piles shall be after the concrete has reached 75 % of its specified
    28 day strength so that the pile is not damaged under the impact stresses.
    as

    (f) Set Measurements


    (i) Where required and appropriate, the permanent penetration per blow and
    se

    temporary compression of the pile and soil system shall be measured


    independently of the instruments being used to record the dynamic test data.
    er

    (g) Results
    ov

    (i) Initial the results shall be provided to the Engineer within 24 hours of the
    completion of a test. These shall include
    o

    1. The maximum force applied to the pile head.


    it
    et

    2. The maximum pile head velocity.


    3. The maximum energy imparted to the pile.
    m

    (ii) Normally within 10 d of the completion of testing final report shall be given to the
    Engineer which includes:
    1. Date of pile installation.
    2. Date of test.
    3. Pile identification number and location.
    4. Length of pile below ground surface.
    5. Total pile length, including projection above commencing surface at time
    of test.
    6. Length of pile from instrumentation position to tip.
    7. Hammer type, drop and other relevant details.
    8. Blow selected for analysis.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 51
    Part 04: Deep Foundations

    9. Test load achieved (i.e. total mobilised deduced static load).


    10. Pile head movement at equivalent design verification load.
    11. Pile head movement at equivalent design verification load plus 50 % of
    specified working load.
    12. Pile head movement at maximum applied test load.
    13. Permanent residual movement of pile head after each blow.
    14. Temporary compression.

    4.10 DESIGN METHODS AND DESIGN CONSIDERATIONS

    4.10.1 Design method

    .
    1 The design shall be based on one of the following approaches:

    l
    .l.
    (a) The results of static load tests, which have been demonstrated, by means of

    rw
    calculations or otherwise, to be consistent with other relevant experience;
    (b) Empirical or analytical calculation methods whose validity has been demonstrated by
    static load tests in comparable situations;
    ta
    qa
    (c) The results of dynamic load tests whose validity has been demonstrated by static load
    tests in comparable situations;
    (d) The observed performance of a comparable piles foundation, provided that this
    as

    approach is supported by the results of site investigation and ground testing.


    se

    2 Design values for parameters used in the calculations should be in general accordance with
    design parameters from geotechnical investigations report, but the results of load tests may
    er

    also be taken into account in selecting parameter values.


    ov

    3 Static load tests may be carried out on trial piles, installed for test purposes only, before the
    design is finalized, or on working piles, which form part of the foundation.
    o

    4.10.2 Verification of Resistance for Structural and Ground Limit States in Persistent and
    it

    Transient Situations
    et
    m

    1 When considering a limit state of rupture or excessive deformation of a structural element or


    section of the ground (Structural and Geotechnical), it shall be verified in accordance with
    (Eurocode1997-1) or equivalent.

    4.10.3 Design Considerations

    1 The behavior of individual piles and pile groups and the stiffness and strength of the structure
    connecting the piles shall be considered.

    2 In selecting calculation methods and parameter values and in using load test results, the
    duration and variation in time of the loading shall be considered.

    3 Planned future placement or removal of overburden or potential changes in the ground-water


    regime shall be considered, both in calculations and in the interpretation of load test results.

    4 The choice of type of pile, including the quality of the pile material and the method of
    installation, shall take into account:
    QCS 2014 Section 04: Foundations and Retaining Structures Page 52
    Part 04: Deep Foundations

    (a) the ground and ground-water conditions on the site, including the presence or
    possibility of obstructions in the ground;
    (b) the stresses generated in the pile during installation;
    (c) the possibility of preserving and checking the integrity of the pile being installed;
    (d) the effect of the method and sequence of pile installation on piles, which have already
    been installed and on adjacent structures or services;
    (e) the tolerances within, which the pile can be installed reliably;
    (f) the deleterious effects of chemicals in the ground;
    (g) the possibility of connecting different ground-water regimes;
    (h) the handling and transportation of piles;
    (i) the effects of pile construction on neighboring buildings.

    l .
    .l.
    5 In considering the aspects listed above, the following items should receive attention:

    rw
    (a) the spacing of the piles in pile groups;
    (b) displacement or vibration of adjacent structures due to pile installation;
    (c) the type of hammer or vibrator used;
    ta
    qa
    (d) the dynamic stresses in the pile during driving;
    (e) for those types of bored pile where a fluid is used inside the borehole, the need to
    as

    keep the pressure of the fluid at a level to ensure that the borehole will not collapse
    and that hydraulic failure of the base will not occur;
    se

    (f) cleaning of the base and sometimes the shaft of the borehole, especially under
    bentonite, to remove remolded materials;
    er

    (g) local instability of a shaft during concreting, which may cause a soil inclusion within
    ov

    the pile;
    (h) ingress of soil or water into the section of a cast-in-situ pile and possible disturbance
    o

    of wet concrete by the flow of water through it;


    it

    (i) the effect of unsaturated sand layers around a pile extracting water from the
    et

    concrete;
    m

    (j) the retarding influence of chemicals in the soil;


    (k) soil compaction due to the driving of displacement piles;
    (l) soil disturbance due to the boring of a pile shaft.

    4.11 AXIALLY LOADED PILES

    4.11.1 Limit state design

    1 The design shall demonstrate that exceeding the following limit states is sufficiently
    improbable:

    (a) ultimate limit states of compressive or tensile resistance failure of a single pile;
    (b) ultimate limit states of compressive or tensile resistance failure of the pile foundation
    as a whole;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 53
    Part 04: Deep Foundations

    (c) ultimate limit states of collapse or severe damage to a supported structure caused by
    excessive displacement or differential displacements of the pile foundation;
    (d) serviceability limit states in the supported structure caused by displacement of the piles.

    2 Normally the design should consider the margin of safety with respect to compressive or
    tensile resistance failure, which is the state in which the pile foundation displaces significantly
    downwards or upwards with negligible increase or decrease of resistance.

    3 For piles in compression it is often difficult to define an ultimate limit state from a load
    settlement plot showing a continuous curvature. In these cases, settlement of the pile top
    equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

    4 For piles that undergo significant settlements, ultimate limit states may occur in supported
    structures before the resistance of the piles is fully mobilized. In these cases a cautious

    l .
    estimate of the possible range of the settlements shall be adopted in design.

    .l.
    rw
    4.11.2 Compressive Ground Resistance

    1 To demonstrate that the pile foundation will support the design load with adequate safety

    ta
    against compressive failure, the following inequality shall be satisfied for all ultimate limit
    qa
    state load cases and load combinations:
    Fc Rc
    as

    Where
    se

    Fc: design axial compression load on a pile or a group of piles


    er

    Rc: design value


    ov

    2 In principle Fc should include the weight of the pile itself and Rc should include the
    overburden pressure of the soil at the foundation base. However these two items may be
    o

    disregarded if they cancel approximately. They need not cancel if:


    it

    (a) downdrag is significant;


    et

    (b) the soil is very light,


    m

    (c) the pile extends above the surface of the ground.

    3 For piles in groups, two failure mechanisms shall be taken into account:

    (a) compressive resistance failure of the piles individually;


    (b) compressive resistance failure of the piles and the soil contained between them acting
    as a block.
    NOTE: The design resistance shall be taken as the lower value caused by these two
    mechanisms.

    4 The compressive resistance of the pile group acting as a block may be calculated by
    treating the block as a single pile of large diameter.

    5 The stiffness and strength of the structure connecting the piles in the group shall be
    considered when deriving the design resistance of the foundation.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 54
    Part 04: Deep Foundations

    6 If the piles support a stiff structure, advantage may be taken of the ability of the structure
    to redistribute load between the piles. A limit state will occur only if a significant numbe r of
    piles fail together; therefore a failure mode involving only one pile need not be considered.

    7 If the piles support a flexible structure, it should be assumed that the compressive
    resistance of the weakest pile governs the occurrence of a limit state.

    8 Special attention should be given to possible failure of edge piles caused by inclined or
    eccentric loads from the supported structure.

    9 If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer
    on the compressive resistance of the foundation shall be considered.

    10 The strength of a zone of ground above and below the pile base shall be taken into
    account when calculating the pile base resistance.

    l .
    .l.
    rw
    NOTE: This zone may extend several diameters above and below the pile base. Any weak
    ground in this zone has a relatively large influence on the base resistance.

    11 ta
    Punching failure should be considered if weak ground is present at a depth of less than 4
    qa
    times the base diameter below the base of the pile.

    12 Where the pile base diameter exceeds the shaft diameter, the possible adverse effect
    as

    shall be considered.
    se

    13 For open-ended driven tube or box-section piles with openings of more than 500 mm in
    any direction, and without special devices inside the pile to induce plugging, the base
    er

    resistance should be limited to the smaller of:


    ov

    (a) the shearing resistance between the soil plug and the inside face of the pile;
    (b) the base resistance derived using the cross-sectional area of the base.
    it o

    4.11.3 Ultimate compressive resistance from static load tests


    et

    1 The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be
    m

    specified in the Geotechnical Design Report.

    2 Trial piles to be tested in advance shall be installed in the same manner as the piles that will
    form the foundation and shall be founded in the same stratum.

    3 If the diameter of the trial pile differs from that of the working piles, the possible difference in
    performance of piles of different diameters should be considered in assessing the
    compressive resistance to be adopted.

    4 In the case of a very large diameter pile, it is often impractical to carry out a load test on a full
    size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

    (a) the ratio of the trial pile diameter/working pile diameter is not less than 0,5;
    (b) the smaller diameter trial pile is fabricated and installed in the same way as the piles
    used for the foundation;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 55
    Part 04: Deep Foundations

    (c) the trial pile is instrumented in such a manner that the base and shaft resistance can be
    derived separately from the measurements.
    NOTE: This approach should be used with caution for open-ended driven piles because of
    the influence of the diameter on the mobilisation of the compressive resistance of a soil plug
    in the pile.

    5 In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a
    displacement that equals the criterion for the verification of the ultimate limit state determined
    from the load test results, shall be corrected. The correction shall be achieved by subtracting
    the measured, or the most unfavorable, positive shaft resistance in the compressible stratum
    and in the strata above, where negative skin friction develops, from the loads measured at
    the pile head.

    6 During the load test of a pile subject to downdrag, positive shaft friction will develop along the

    .
    total length of the pile. The maximum test load applied to the working pile should be in excess

    l
    .l.
    of the sum of the design external load plus twice the downdrag force.

    rw
    7 When deriving the ultimate characteristic compressive resistance from values measured in
    one or several pile load tests, an allowance shall be made for the variability of the ground and
    the variability of the effect of pile installation.
    ta
    qa
    8 The systematic and random components of the variations in the ground shall be recognized
    in the interpretation of pile load tests.
    as

    9 The records of the installation of the test pile(s) shall be checked and any deviation from the
    normal execution conditions shall be accounted for.
    se

    10 The characteristic compressive resistance of the ground may be derived from the
    er

    characteristic values of the base resistance and of the shaft resistance in accordance with
    Eurocode1997-1.
    ov

    4.11.4 Ultimate compressive resistance from ground test results


    o

    1 Methods for assessing the compressive resistance of a pile foundation from ground test
    it

    results shall have been established from pile load tests and from comparable experience.
    et
    m

    2 A model factor may be introduced as described as following to ensure that the predicted
    compressive resistance is sufficiently safe :

    (a) the range of uncertainty in the results of the method of analysis;


    (b) any systematic errors known to be associated with the method of analysis

    3 In assessing the validity of a model based on ground test results, the following items should
    be considered:

    (a) soil type, including grading, mineralogy, angularity, density, pre-consolidation,


    compressibility and permeability;
    (b) method of installation of the pile, including method of boring or driving;
    (c) length, diameter, material and shape of the shaft and of the base of the pile (e.g.
    enlarged base);
    (d) method of ground testing.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 56
    Part 04: Deep Foundations

    4.11.5 Ultimate compressive resistance from dynamic impact tests

    1 Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration
    versus time during the impact event is used to assess the resistance of individual
    compression piles, the validity of the result shall have been demonstrated by previous
    evidence of acceptable performance in static load tests on the same pile type of similar
    length and cross-section and in similar ground conditions.

    2 When using a dynamic impact load test, the driving resistance of the pile should be
    measured directly on the site in question.

    NOTE A load test of this type can also include a process of signal matching to
    measured stress wave figures. Signal matching enables an approximate evaluation of shaft
    and base resistance of the pile as well as a simulation of its load-settlement behaviour.

    .
    3 The impact energy shall be high enough to allow for an appropriate interpretation of

    l
    .l.
    the pile capacity at a correspondingly high enough strain level.

    rw
    4 The design value of the compressive resistance of the pile could be calculated and
    verified according to Eurocode1997-1.

    4.11.6 ta
    Ultimate compressive resistance by applying pile driving formulae
    qa
    1 Pile driving formulae shall only be used if the stratification of the ground has been
    determined.
    as

    2 If pile driving formulae are used to assess the ultimate compressive resistance of individual
    se

    piles in a foundation, the validity of the formulae shall have been demonstrated by previous
    experimental evidence of acceptable performance in static load tests on the same type of
    er

    pile, of similar length and cross-section, and in similar ground conditions.


    ov

    3 For end-bearing piles driven into non-cohesive soil, the design value of the compressive
    resistance shall be assessed by the same procedure as in 4.11.5.
    o

    4 When a pile driving formula is applied to verify the compression resistance of a pile, the pile
    it

    driving test should have been carried out on at least 5 piles distributed at sufficient spacing in
    et

    the piling area in order to check a suitable blow count for the final series of blows.
    m

    5 The penetration of the pile point for the final series of blows should be recorded for each pile.

    4.11.7 Ultimate compressive resistance from wave equation analysis

    1 Wave equation analysis shall only be used where stratification of the ground has been determined
    by borings and field tests.

    2 Where wave equation analysis is used to assess the resistance of individual compression piles,
    the validity of the analysis shall have been demonstrated by previous evidence of acceptable
    performance in static load tests on the same pile type, of similar length and cross- section, and in
    similar ground conditions.

    3 The design value of the compressive resistance derived from the results of wave equation analysis
    of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 57
    Part 04: Deep Foundations

    NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving
    equipment without stress wave measurements on site. The method is usually applied to
    study hammer performance, dynamic soil parameters and stresses in the pile during driving.
    It is also, on the basis of the models, possible to determine the required driving resistance
    (blow count) that is usually related to the expected compressive resistance of the pile.

    4.11.8 Ground tensile resistance

    1 The design of piles in tension shall be consistent with the design rules given in 4.11.2, where
    applicable. Design rules that are specific for foundations involving piles in tension are presented
    below.

    2 To verify that the foundation will support the design load with adequate safety against a failure in
    tension, the following inequality shall be satisfied for all ultimate limit state load cases and load
    combinations in accordance with Eurocode1997-1.

    l .
    .l.
    3 For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the

    rw
    pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

    4 When considering the uplift of the block of ground containing the piles the shear resistance along

    ta
    the sides of the block may be added to the resisting forces.
    qa
    5 Normally the block effect will govern the design tensile resistance if the distance between the piles
    is equal to or less than the square root of the product of the pile diameter and the pile penetration
    into the main resisting stratum.
    as

    6 The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft
    se

    resistances of individual piles in the group, shall be considered when assessing the tensile
    resistance of a group of piles.
    er

    7 The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be
    ov

    considered.
    o

    8 Comparable experience based on pile load tests should be applied to appraise this effect.
    it
    et

    4.11.9 Ultimate tensile resistance from pile load tests


    m

    1 Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in
    accordance with 4.9.1 and with regard to 4.11.3.

    2 The design tensile resistance could be calculated and verified according to Eurocode1997-1.

    4.11.10 Ultimate tensile resistance from ground test results

    1 Methods for assessing the tensile resistance of a pile foundation from ground test results shall
    have been established from pile load tests and from comparable experience.

    2 A model factor may be introduced as following to ensure that the predicted tensile resistance is
    sufficiently safe.

    (a) the range of uncertainty in the results of the method of analysis;


    (b) any systematic errors known to be associated with the method of analys is
    QCS 2014 Section 04: Foundations and Retaining Structures Page 58
    Part 04: Deep Foundations

    3 The design value of tensile resistance of a pile could be calculated and verified according to
    Eurocode1997-1.

    4.11.11 Vertical displacements of pile foundations

    1 Vertical displacements under serviceability limit state conditions shall be assessed and checked.

    2 When calculating the vertical displacements of a pile foundation, the uncertainties involved in the
    calculation model and in determining the relevant ground properties should be taken into account.
    Hence it should not be overlooked that in most cases calculations will provide only an approximate
    estimate of the displacements of the pile foundation.

    NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety
    requirements for the ultimate limit state design are normally sufficient to prevent a
    serviceability limit state in the supported structure.

    l .
    .l.
    4.11.12 Pile foundations in compression

    rw
    1 The occurrence of a serviceability limit state in the supported structure due to pile settlements shall
    be checked, taking into account downdrag, where probable.

    ta
    NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very
    qa
    hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to
    satisfy serviceability limit state conditions.
    as

    2 Assessment of settlements shall include both the settlement of individual piles and the settlement
    due to group action.
    se

    3 The settlement analysis should include an estimate of the differential settlements that may occur.
    er

    4 When no load test results are available for an analysis of the interaction of the piled foundation with
    ov

    the superstructure, the load-settlement performance of individual piles should be assessed on


    empirically established safe assumptions.
    o

    4.11.13 Pile foundations in tension


    it
    et

    1 The assessment of upward displacements shall be done and Particular attention should be paid to
    the elongation of the pile material.
    m

    2 When very severe criteria are set for the serviceability limit state, a separate check of the upward
    displacements shall be carried out.

    4.12 TRANSVERSELY LOADED PILES

    4.12.1 Design method

    1 The design of piles subjected to transverse loading shall be consistent with the design rules given
    in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to
    transverse loading are presented below.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 59
    Part 04: Deep Foundations

    2 To demonstrate that a pile will support the design transverse load with adequate safety against
    failure, the following inequality shall be satisfied for all ultimate limit state load cases and load
    combinations:

    Ftr Rtr

    Where;
    Ftr: design value of the transverse load on a pile or a pile foundation
    Rtr : design resistance of transversally loaded pile

    3 One of the following failure mechanisms should be considered:

    (a) for short piles, rotation or translation as a rigid body;

    .
    (b) for long slender piles, bending failure of the pile, accompanied by local yielding and

    l
    .l.
    displacement of the soil near the top of the pile.

    rw
    4 The group effect shall be considered when assessing the resistance of transversely loaded piles.

    5 It should be considered that a transverse load applied to a group of piles may result in a

    ta
    combination of compression, tension and transverse forces in the individual piles.
    qa
    4.12.2 Transverse load resistance from pile load tests
    as

    1 Transverse pile load tests shall be carried out in accordance with 4.9.6.
    se

    2 Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not
    normally be continued to a state of failure. The magnitude and line of action of the test load should
    simulate the design loading of the pile.
    er
    ov

    3 An allowance shall be made for the variability of the ground, particularly over the top few meters of
    the pile, when choosing the number of piles for testing and when deriving the design transverse
    resistance from load test results.
    it o

    4 Records of the installation of the test pile(s) should be checked, and any deviation from the normal
    et

    construction conditions should be accounted for in the interpretation of the pile load test results.
    For pile groups, the effects of interaction and head fixity should be accounted for when deriving the
    m

    transverse resistance from the results of load tests on individual test piles.

    4.12.3 Transverse load resistance from ground test results and pile strength parameters

    1 The transverse resistance of a pile or pile group shall be calculated using a compatible set of
    structural effects of actions, ground reactions and displacements.

    2 The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile
    in the ground.

    3 The calculation of the transverse resistance of a long slender pile may be carried out using the
    theory of a beam loaded at the top and supported by a deformable medium characterized by a
    horizontal modulus of subgrade reaction.

    4 The degree of freedom of rotation of the piles at the connection with the structure shall be taken
    into account when assessing the foundations transverse resistance.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 60
    Part 04: Deep Foundations

    4.12.4 Transverse displacement

    1 The assessment of the transverse displacement of a pile foundation shall take into account:

    (a) the stiffness of the ground and its variation with strain level;
    (b) the flexural stiffness of the individual piles;
    (c) the moment fixity of the piles at the connection with the structure;
    (d) the group effect;
    (e) the effect of load reversals or of cyclic loading

    2 A general analysis of the displacement of a pile foundation should be based on expected degrees
    of kinematic freedom of movement.

    l .
    END OF PART

    .l.
    rw
    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 04: Foundations & Retaining Structures Page 2
    Part 05: Retaining Structures

    5 RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

    5.1 GENERAL---------------------------------------------------------------------------------------------------------- 2

    5.2 LIMIT STATES ---------------------------------------------------------------------------------------------------- 2


    5.2.2 Ultimate Limit State ---------------------------------------------------------------------------------------------- 2
    5.2.3 Serviceability Limit State ---------------------------------------------------------------------------------------- 3
    5.3 ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3
    5.3.1 Actions -------------------------------------------------------------------------------------------------------------- 3
    5.3.2 Geometrical data ------------------------------------------------------------------------------------------------- 4
    5.3.3 Design Situations ------------------------------------------------------------------------------------------------- 4
    5.4 DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

    5.5 DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

    l .
    .l.
    5.5.1 General ------------------------------------------------------------------------------------------------------------- 6
    5.5.2 At rest values of earth pressure------------------------------------------------------------------------------- 7

    rw
    5.5.3 Limiting values of earth pressure ----------------------------------------------------------------------------- 7
    5.5.4 Intermediate values of earth pressure ----------------------------------------------------------------------- 7
    5.5.5
    5.6 ta
    Compaction effects ---------------------------------------------------------------------------------------------- 7
    WATER PRESSURES ------------------------------------------------------------------------------------------ 8
    qa
    5.7 ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8
    as

    5.7.1 General ------------------------------------------------------------------------------------------------------------- 8


    5.7.2 Overall stability ---------------------------------------------------------------------------------------------------- 8
    se

    5.7.3 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8


    5.7.4 Rotational failure of embedded walls ------------------------------------------------------------------------ 8
    er

    5.7.5 Vertical failure of embedded walls --------------------------------------------------------------------------- 9


    5.7.6 Structural design of retaining structures -------------------------------------------------------------------- 9
    ov

    5.7.7 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9


    5.8 SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9
    o

    5.8.1 General ------------------------------------------------------------------------------------------------------------- 9


    it

    5.8.2 Displacements ---------------------------------------------------------------------------------------------------- 9


    et
    m
    QCS 2014 Section 04: Foundations & Retaining Structures Page 2
    Part 05: Retaining Structures

    5 RETAINING STRUCTURES

    5.1 GENERAL

    1 The provisions of this Part 5 apply to retaining structures in general. These are structures
    used to retain ground comprising soil, rock or backfill and water and this at an angle steeper
    than the angle they would normally adopt without the presence of those structures. Common
    retaining structures used within the state of Qatar taking into account the prevailing geologic
    conditions are:

    (a) Sheet Piles


    (b) Bored and Cast in Place Concrete Piles

    l .
    (i) Contiguous Piles

    .l.
    (ii) Secant Piles

    rw
    (c) Diaphragm Walls
    (d) Composite Shoring Systems
    (e) Concrete Retaining Walls ta
    qa
    (i) Cantilever Retaining Wall
    (ii) Counter Fort Retaining Wall
    as

    (iii) Gravity Retaining Wall


    se

    (iv) Buttressed Retaining Wall


    er

    (f) Reinforced Soil Retaining Structures


    (i) Geogrid and Geotextile Reinforced Earth Systems
    ov

    (ii) Galvanized Strips Reinforced Earth System


    o

    (g) Soil and Rock Nailing Systems


    it

    2 This revision of Section 4 Part 5 is considered preliminary and shall be reviewed and
    et

    amended as needed in the next revision to elaborate on various subjects not covered herein.
    m

    3 This revision of Section 4 Part 5 is based generally on EN1997-1:2004+A1:2013


    Eurocode 7.

    4 Section 4 Part 5 will cover at this stage the general design aspects knowing that the
    construction procedures shall be added in future revisions of this Section. Hence, at this
    stage, the construction related subjects of the retaining structures will follow relevant Parts of
    the QCS.

    5.2 LIMIT STATES

    1 During the design of retaining structures the following typical limit states should be
    considered:

    5.2.2 Ultimate Limit State

    1 Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 3
    Part 05: Retaining Structures

    2 Foundation failure of retaining structures with footings: it should be demonstrated that the
    foundation pressures (lateral and vertical) do not exceed neither the ground allowable
    bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to
    water seepage should also be included in the analysis.

    3 Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a
    rigid body.

    4 Failure of embedded walls by rotation or horizontal translation or by lack of vertical


    equilibrium.

    5 Failure of a structural element such as a wall, anchorage, wale or strut, including failure of
    the connection between those elements.

    6 Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable

    l .
    leakage of water, or transport of soil particles through or under the wall caused by excessive

    .l.
    hydraulic gradients.

    rw
    5.2.3 Serviceability Limit State

    1
    ta
    Unacceptable movement of the retaining structure, which may affect the appearance or
    functionality of the structure itself, or other neighbouring structures or utilities influenced by
    qa
    the movement.
    as

    2 Unacceptable change in the groundwater regime.


    se

    5.3 ACTIONS AND GEOMETRICAL DATA


    er

    5.3.1 Actions
    ov

    1 Generally, the forces exerted on retaining structure with values assumed known at the
    beginning of the calculation are considered as 'actions', while forces with initially unknown
    values, to be determined by the interaction of the retaining structure with support elements
    o

    (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following
    it

    actions are to be taken into account:


    et

    (a) Weight of backfill material


    m

    (b) Surcharges
    (c) Weight of water
    (d) Wave forces for marine projects
    (e) Seepage forces
    (f) Collision forces
    (g) Temperature effects
    (h) Forces from propping elements (i.e. post-tensioned anchors)
    (i) Siesmic related effects

    2 The above actions should result in the determination of various earth pressures acting on the
    retaining structure.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 4
    Part 05: Retaining Structures

    5.3.2 Geometrical data

    1 This paragraph covers the uncertainties in the geometrical data namely excavation and water
    levels. In general, small variations in geometrical data are considered to be covered by the
    safety factors included in the calculations. However, since the design of retaining structures
    is sensitive to ground and water levels, special requirements are included in this paragraph,
    mainly for unforeseen over-dig in front of the wall and groundwater levels change on both
    sides of the wall.

    2 Unforeseen over-dig in front of the wall

    In Ultimate Limit State design calculations, where the wall stability depends on the earth
    resistance in front of the wall, the level of the resisting soil should be lowered below the
    nominally expected level by an amount which depends on the degree of control on the
    excavation level. With a normal degree of control the expected difference in resisting soil

    .
    level should be:

    l
    .l.
    (a) Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for
    cantilever walls;

    rw
    (b) Equal to 10% of the distance between the lowest support and the excavation level (up
    to a maximum of 0.5 m), for supported walls.

    3 Groundwater levels in front of and behind the wall ta


    qa
    The selection of the levels of the phreatic surfaces in front of and behind the wall must
    consider long-term variations of the groundwater regime and/or the ground permeability, the
    as

    presence of perched or artesian aquifers and the possibility that drainage behind the wall
    may cease to function with time.
    se

    5.3.3 Design Situations


    er

    1 The following conditions shall be considered during the design of retaining structures:
    ov

    (a) Anticipated variations in soil properties


    (b) Variations in actions and the ways they are combined
    it o

    (c) Excavation, scour or erosion in front of the retaining structure


    et

    (d) The effect of compaction of the backfill behind the retaining structure
    m

    (e) The effect of anticipated future structures and surcharge loads/unloads


    (f) Anticipated ground movements
    (g) Inclination of the wall to the vertical
    (h) Variations in groundwater table and the seepage forces in the ground
    (i) Horizontal as well as vertical equilibrium for the entire retaining structure
    (j) The shear strength and weight density of the ground
    (k) The rigidity of the wall and the supporting system
    (l) The wall roughness
    (m) Seismic effect on the various forces
    QCS 2014 Section 04: Foundations & Retaining Structures Page 5
    Part 05: Retaining Structures

    5.4 DESIGN AND CONSTRUCTION CONSIDERATIONS

    1 The design of retaining structures requires consideration of all relevant Ultimate Service
    States and Service Limit States.

    2 For retaining structures without strict serviceability requirements, the geometry is usually
    determined by Ultimate Limit State design calculations and checked by Service Limit State
    calculations (if relevant). For the retaining structures with strict serviceability requirements,
    the Service Limit State requirements often govern the design.

    3 The design and construction considerations should cover the following:

    (a) Demonstrate that vertical equilibrium can be achieved for the assumed pressure
    distributions and actions on the wall.

    .
    (b) Verification of vertical equilibrium may be achieved by reducing the wall friction

    l
    .l.
    parameters.

    rw
    (c) Retaining walls should be designed in such a way that there are visible signs of the
    approach of an ultimate limit state. The design should prevent brittle failure of the
    structure, e.g. sudden collapse without conspicuous preliminary deformations.
    (d) ta
    A critical limit state should be considered to occur if the wall has displaced enough to
    qa
    cause damage to nearby structures or services. Although collapse of the wall may not
    be imminent, the degree of damage may considerably exceed a serviceability limit
    state in the supported structure.
    as

    (e) The design methods and partial factor values recommended by EN1997-
    1:2004+A1:2013 are usually sufficient to prevent the occurrence of ultimate limit
    se

    states in nearby structures, provided that the soils involved are of at least medium
    er

    density or firm consistency and adequate construction methods and sequences are
    adopted. Special care should be taken, however, with some highly over-consolidated
    ov

    clay deposits in which large at rest horizontal stresses may induce substantial
    movements in a wide area around excavations.
    o

    (f) The complexity of the interaction between the ground and the retaining structure
    it

    sometimes makes it difficult to design a retaining structure in detail before the actual
    et

    execution starts. In this case, use of the observational method for the design should be
    considered. The observational method consists of setting criteria enabling monitoring
    m

    during construction, allowing necessary corrective actions to be taken to rectify the


    design. Hence, the following requirements shall be set before construction:
    (i) Acceptable limits of behaviour
    (ii) The range of potential behaviour shall be analysed showing acceptable
    probability that the actual behaviour will be within the acceptable limits
    (iii) A plan of monitoring shall be established (including necessary instruments and
    procedures) enabling the comparison of the actual behaviour to the acceptable
    limits. The monitoring shall allow early detection of nonconformities, allowing
    enough time for corrective actions to be taken successfully.
    (iv) A list of contingency actions shall be established which could be used if the
    actual observed behaviour is outside of the acceptable limits.
    (g) The effects of constructing the wall, including:
    (i) The provision of temporary support to the sides of excavations;
    QCS 2014 Section 04: Foundations & Retaining Structures Page 6
    Part 05: Retaining Structures

    (ii) The changes of in situ stresses and resulting ground movements caused both
    by the wall excavation and its construction;
    (iii) Disturbance of the ground due to driving or boring operations;
    (iv) Provision of access for construction;

    (h) The required degree of water tightness of the finished wall;


    (i) The practicability of constructing the wall to reach a stratum of low permeability, so
    forming a water cut-off. The resulting equilibrium ground-water flow problem shall be
    assessed;
    (j) The practicability of forming ground anchorages in adjacent ground;
    (k) The practicability of excavating between any propping of retaining walls;

    .
    (l) The ability of the wall to carry vertical load;

    l
    .l.
    (m) The ductility of structural components;

    rw
    (n) Access for maintenance of the wall and any associated drainage measures;
    (o) The appearance and durability of the wall and any anchorages;
    (p)
    ta
    For sheet piling, the need for a section stiff enough to be driven to the design
    qa
    penetration without loss of interlock;
    (q) The stability of borings or slurry trench panels while they are open;
    as

    (r) For fill, the nature of materials available and the means used to compact them
    adjacent to the wall.
    se

    (s) Drainage systems


    er

    If the safety and serviceability of the designed structure depend on the successful
    performance of a drainage system, the consequences of its failure shall be
    ov

    considered, taking into account both safety and cost of repair. One of the following
    conditions (or a combination of them) shall apply:
    o

    (i) A maintenance program for the drainage system shall be specified and the
    it

    design shall allow access for this purpose;


    et

    (ii) It shall be demonstrated both by comparable experience and by assessment of


    m

    any water discharge that the drainage system will operate adequately without
    maintenance.

    The quantities, pressures and eventual chemical content of any water discharge
    should be taken into account.

    5.5 DETERMINATION OF EARTH PRESSURES

    5.5.1 General

    1 The Determination of the earth pressures shall take into account the acceptable mode and
    amount of any movement and strain, which may occur at the limit state under consideration.

    2 In the following context the words "earth pressure" should also be used for the total earth
    pressure from soft and weathered rocks and should include the pressure of ground-water.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 7
    Part 05: Retaining Structures

    3 Calculations of the magnitudes of earth pressures and directions of forces resulting from
    them shall take account of the issues highlighted under paragraph 5.3.3.

    4 The amount of mobilized wall friction and adhesion should be considered as a function of:

    (a) The strength parameters of the ground


    (b) The friction properties of the wall-ground interface
    (c) The direction and amount of movement of the wall relative to the ground
    (d) The ability of the wall to support any vertical forces resulting from wall friction and
    adhesion

    5 A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a
    design wall ground interface parameter d k. cv ;d . k should not exceed 2/3 for precast

    .
    concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be

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    assumed. For a steel sheet pile in clay under undrained conditions immediately after driving,
    no adhesive or frictional resistance should be assumed. Increases in these values may take

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    place over a period of time.

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    6 In the case of structures retaining rock masses, calculations of the ground pressures shall
    take into account the effects of discontinuities, with particular attention to their orientation,
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    spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

    7 Account shall be taken of any swelling potential of the ground when calculating the pressures
    as

    on the retaining structure.


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    5.5.2 At rest values of earth pressure


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    1 When no movement of the wall relative to the ground takes place, the earth pressure shall be
    calculated from the at rest state of stress. The determination of the at-rest state shall take
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    into account the stress history of the ground.

    5.5.3 Limiting values of earth pressure


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    1 Limiting values of earth pressures shall be determined taking into account the relative
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    movement of the soil and the wall at failure and the corresponding shape of the failure
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    surface.

    5.5.4 Intermediate values of earth pressure

    1 Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize
    the limiting values. The determination of the intermediate values of earth pressure shall take
    into account the amount of wall movement and its direction relative to the ground.

    2 The intermediate values of earth pressures may be calculated using, for example, various
    empirical rules, spring constant methods or finite element methods.

    5.5.5 Compaction effects

    1 The determination of earth pressures acting behind the wall shall take into account the
    additional pressures generated by any placing of backfill and the procedures adopted for its
    compaction.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 8
    Part 05: Retaining Structures

    5.6 WATER PRESSURES

    1 Determination of characteristic and design water pressures shall take account of water levels
    both above and in the ground.

    2 When checking the ultimate and serviceability limit water pressures shall be accounted for in
    the combinations of actions considering the possible risks of flooding or change in
    groundwater levels from either sides of the retaining structure.

    3 For structures retaining earth of medium or low permeability (silts and clays), water pressures
    should normally be assumed to act behind the wall. Unless a reliable drainage system is
    installed, or infiltration is prevented, the values of water pressures should normally
    correspond to a water table at the surface of the retained material.

    4 Where sudden changes in a free water level may occur, both the non-steady condition

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    occurring immediately after the change and the steady condition shall be examined.

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    5 Where no special drainage or flow prevention measures are taken, the possible effects of
    water-filled tension or shrinkage cracks shall be considered.

    5.7 ULTIMATE LIMIT STATE DESIGN


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    5.7.1 General
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    1 The design of retaining structures shall be checked at the ultimate limit state for the design
    situations appropriate to that state, as specified in 5.3.3, using the design actions or action
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    effects and design resistances.


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    2 All relevant limit modes shall be considered. These will include, as a minimum, limit modes of
    the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.
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    3 Calculations for ultimate limit states shall establish that equilibrium can be achieved using the
    design actions or effects of actions and the design strengths or resistances. Compatibility of
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    deformations shall be considered in assessing design strengths or resistances.


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    5.7.2 Overall stability


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    1 Principles and calculations should be used as appropriate to demonstrate that an overall


    stability failure will not occur and that the corresponding deformations are sufficiently small
    taking into account progressive failure and liquefaction into account as relevant.

    5.7.3 Foundation failure of gravity walls

    1 The principles of foundation design shall be used as appropriate to demonstrate that a


    foundation failure is sufficiently remote and that deformations will be acceptable. Both
    bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should
    be verified as a minimum.

    5.7.4 Rotational failure of embedded walls

    1 It shall be demonstrated by equilibrium calculations that embedded walls have sufficient


    penetration into the ground to prevent rotational failure. As a minimum, limit modes of the
    types illustrated in Figure 5.3 should be considered.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 9
    Part 05: Retaining Structures

    2 The design magnitude and direction of shear stress between the soil and the wall shall be
    consistent with the relative vertical displacement, which would occur in the design situation.

    5.7.5 Vertical failure of embedded walls

    1 It shall be demonstrated that vertical equilibrium can be achieved using the design soil
    strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode
    of the type illustrated in Figure 5.4 should be considered.

    2 Where downward movement of the wall is considered, upper design values shall be used in
    the calculation of pre-stressing forces, such as those from ground anchorages, which have a
    vertical downward component. The design magnitude and direction of shear stress between
    the soil and the wall shall be consistent with the check for vertical and rotational equilibrium.
    If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using
    the principles of Pile Foundations Design.

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    5.7.6 Structural design of retaining structures

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    1 Retaining structures, including their supporting structural elements such as anchorages and
    props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013

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    2.4 Geotechnical Design by Calculation and EN1992, EN1993, EN1995 and EN1996. As a
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    minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

    5.7.7 Failure by pull-out of anchorages


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    1 It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground
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    anchorages. Anchors shall be designed in accordance with Anchorage Design procedures


    with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be
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    considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also
    be considered.
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    5.8 SERVICEABILITY LIMIT STATE DESIGN


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    5.8.1 General
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    1 The design of retaining structures shall be checked at the serviceability limit state using the
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    appropriate design situations as specified in 5.3.3. The assessment of design values of earth
    pressures should take account of the initial stress, stiffness and strength of the ground and
    the stiffness of the structural elements.

    2 The design values of earth pressures should be derived taking account of the allowable
    deformation of the structure at its serviceability limit state. These pressures need not
    necessarily be limiting values.

    5.8.2 Displacements

    1 Limiting values for the allowable displacements of walls and the ground adjacent to them
    shall be established for a particular deformation is the value at which a serviceability limit
    state, such as unacceptable cracking or displacement of adjacent structures or utilities, is
    deemed to occur. This limiting value shall be agreed during the design, taking into account
    the tolerance to displacements of supported structures and services.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 10
    Part 05: Retaining Structures

    2 If the initial cautious estimate of displacement exceeds the limiting values, the design shall be
    justified by a more detailed investigation including displacement calculations.

    3 It shall be considered to what extent variable actions, such as vibrations caused by traffic
    loads behind the retaining wall, contribute to the wall displacement.

    4 Displacement calculations should also be considered in the following cases:

    (a) where the wall retains more than 6m of cohesive soil of low plasticity,
    (b) where the wall retains more than 3m of soils of high plasticity;
    (c) where the wall is supported by soft clay within its height or beneath its base.

    5 Displacement calculations shall take into account the stiffness of the ground and structural
    elements and the sequence of construction.

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    6 The effect of vibrations on displacements shall be considered with regard to the following:

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    (a) Foundations for structures subjected to vibrations or to vibrating loads shall be
    designed to ensure that vibrations will not cause excessive settlements.
    (b)
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    Precautions should be taken to ensure that resonance will not occur between the
    frequency of the dynamic load and a critical frequency in the foundation-ground
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    system, and to ensure that liquefaction will not occur in the ground.
    (c) Vibrations caused by earthquakes shall be considered using the guidelines of the
    as

    designated section of the QCS.


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    Figure 5.1 Examples of Limit Modes for Overall Stability of Retaining Structures
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 11
    Part 05: Retaining Structures

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    Figure 5.2 Examples of Limit Modes for Foundation Failures of Gravity Walls

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    (EN 1997-1:2004+A1:2013)
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    Figure 5.3 Examples of Limit Modes for Rotational Failures of Embedded Walls
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 12
    Part 05: Retaining Structures

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    Figure 5.4 Example of a Limit Mode for Vertical Failure of Embedded Walls
    (EN 1997-1:2004+A1:2013)

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    Figure 5.5 Examples of Limit Modes for Structural Failure of Retaining Structures
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 13
    Part 05: Retaining Structures

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    Figure 5.6 Examples of Limit Modes for Failure by Pull-out of Anchoes
    (EN 1997-1:2004+A1:2013)

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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 01: General

    1 GENERAL------------------------------------------------------------------------------------------------------------ 2

    1.1 INTRODUCTION --------------------------------------------------------------------------------------------------- 2


    1.1.1 Scope ----------------------------------------------------------------------------------------------------------------- 2
    1.1.2 References----------------------------------------------------------------------------------------------------------- 2
    1.1.3 Definitions ------------------------------------------------------------------------------------------------------------ 3
    1.1.4 Approved Products ------------------------------------------------------------------------------------------------ 4

    1.2 IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4


    1.2.1 Approved Installers ------------------------------------------------------------------------------------------------ 4
    1.2.2 Field Quality Control ----------------------------------------------------------------------------------------------- 4
    1.2.3 Rejected materials ------------------------------------------------------------------------------------------------- 5
    1.2.4 Records --------------------------------------------------------------------------------------------------------------- 5

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    QCS 2014 Section 05: Concrete Page 2
    Part 01: General

    1 GENERAL

    1.1 INTRODUCTION

    1.1.1 Scope

    1 This Section includes the requirements for concrete work for pipelines, roadworks, runways,
    structures, water retaining structures, foundations and bases for structures and equipment.

    2 This Part includes relevant standards, definitions, abbreviations, and requirements for testing
    facilities, rejected materials, and record keeping.

    3 Related Sections are as follows:


    This Section:

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    Part 2, Aggregates

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    Part 3, Cementitious Materials

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    Part 4, Water
    Part 5, Admixtures
    Part 6, Property Requirements
    Part 7, Concrete Plants
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    Part 8, Transportation and Placing of Concrete
    Part 9, Formwork
    Part 10, Curing
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    Part 11, Reinforcement


    Part 12, Construction Joints
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    Part 13, Inspection and Testing of Hardened Concrete


    Part 14, Protective Coatings to Concrete
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    Part 15, Hot Weather Concrete


    Part 16, Miscellaneous
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    Part 17, Precast Concrete


    Part 18, Prestressed Concrete
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    Part 19, Water Retaining Structures


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    Section 1, General
    Section 2, Quality Assurance and Quality Control
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    Section 4, Foundations and Retaining Structures


    Section 6, Roadworks
    Section 8, Drainage Works
    Section 9, Mechanical and Electrical Equipment

    1.1.2 References

    1 The following standards are referred to in this Part:


    ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in
    the Field
    ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical
    Concrete Specimens
    ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete
    ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed Hydraulic-
    Cement Concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 01: General

    BS 6100, ....................Glossary of Building and civil engineering terms


    BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling
    BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing
    laboratory samples
    BS EN 12350-1 ..........Method of sampling fresh concrete in site
    BS EN 12350-2 ..........Testing fresh concrete. Slump-test
    BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds
    BS EN 12390-2 .......... Making and curing specimens for strength tests
    GSO ISO 1920-1 ........Testing of concrete Part 1: Sampling of fresh concrete
    GSO ISO 1920-2 ........Testing of concrete Part 2: Properties of fresh concrete
    GSO ISO 1920-3 ........Testing of concrete Part 3: Making and curing test specimens

    1.1.3 Definitions

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    1 Definitions used in this Section.

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    The following are terms and abbreviations used:
    C degree Celsius
    cal
    cm
    calorie
    centimetre ta
    qa
    d day
    fck,cyl Characteristic compressive strength of concrete determined by testing cylinders
    fc,cyl Compressive strength of concrete determined by testing cylinders
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    fck,cube Characteristic compressive strength of concrete determined by testing cubes


    fc,cube Compressive strength of concrete determined by testing cubes
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    fcm Mean compressive strength of concrete


    fcm,j Mean compressive strength of concrete at the age of (j) days
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    GGBS ground granulated blast furnace slag


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    GUTS guaranteed ultimate tensile strength


    h hour
    kg kilogram
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    kJ kilojoule
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    kN kilonewton
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    l litre
    m metre
    m

    2
    m square metre
    3
    m cubic metre
    mg milligram
    min minute
    mm millimetre
    2
    mm square millimetre
    months months
    MPa mega Pascal
    kPa kilo Pascal
    MSRPC moderate sulphate resisting Portland cement
    OPC ordinary Portland cement
    PFA pulverised fuel ash
    PVC polyvinylchloride
    s second
    SF silica fume
    SRPC sulphate resisting Portland cement
    QCS 2014 Section 05: Concrete Page 4
    Part 01: General

    ton 1000 kg
    ppm part per million
    -6
    micron 10
    -6
    m 10 meter

    2 Reference to a technical society, institution, association or governmental authority is made in


    accordance with the following abbreviations.
    AASHTO American Association of State Highway and Transportation Officials
    ACI American Concrete Institute
    ASTM American Society for Testing and Materials
    AWS American Welding Society
    BS British Standard
    BSCP British Standard Code of Practice
    BSI British Standards Institution

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    C & CA Cement and Concrete Association
    CIRIA Construction Industry Research and Information Association

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    CRSI Concrete Reinforcing Steel Institute
    CS Concrete Society
    DIN Deutsches Institut fur Normung e.V.
    EN Euro Norm
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    FHWA Federal Highway Authority
    GSO GCC Standardization Organization
    ICE Institution of Civil Engineers
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    ISO International Organization for Standardization


    PCI Prestressed Concrete Institute
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    QCS Qatar Construction Specifications


    QS Qatar Standards
    er

    UK DfT United Kingdom Department for Transport


    Products
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    1.1.4 Approved Products


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    1 The contract specific documentation may identify approved products and approved or
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    prequalified manufacturers and suppliers of products used in concrete work.


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    1.2 IMPLEMENTATION

    1.2.1 Approved Installers

    1 The contract specific documentation may identify approved or prequalified providers of


    concrete construction services.

    1.2.2 Field Quality Control

    1 The Contractor shall carry out the test procedures required by this Section and any other
    tests and test procedures as directed by the Engineer from time to time. The test procedures
    shall be carried out using the facilities of an approved independent testing laboratory.

    2 Supply, storage, sampling and testing of all materials shall be the responsibility of the
    Contractor, unless the Contract specifies otherwise.
    QCS 2014 Section 05: Concrete Page 5
    Part 01: General

    3 The Engineer may also require the Contractor to take samples of materials and deliver them
    to the Central Materials Laboratory for additional tests to be carried out by the Employer.
    Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards,
    and sample sizes shall conform to the requirements shown in Table 1.1.

    4 The minimum equipment required for testing on Site is given in Table 1.2. This equipment
    shall be maintained on Site at all times during concreting operations together with the
    necessary scoops, buckets, sample containers, and other items required for sampling. The
    cube curing tank shall be located in an air-conditioned area as stated in part 06.

    1.2.3 Rejected materials

    1 Any material rejected by the Engineer, in particular cement which has deteriorated or
    aggregates which have segregated or become contaminated, shall be immediately removed
    from the Site.

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    1.2.4 Records

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    1 The Contractor shall maintain on the Site full records of all work carried out accurately
    related to the location of the work on site, which shall include:
    (a) the time and date when all concrete was poured, formwork removed and when
    formwork props were fully removed ta
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    (b) all cubes and other tests
    (c) daily maximum and minimum temperatures.
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    2 One copy of all test results shall be sent to the Engineer immediately upon completion of the
    se

    tests
    Table 1.1
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    Sampling Procedure and


    Minimum Sample Sizes for Central Materials Laboratory
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    Material Test Min. Sample


    Composite sample of 7 kg
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    Cement Full range of tests


    taken from at least 12 bags
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    Full range of tests 200 kg


    Sieve analysis
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    Chemical analysis
    Soundness test
    Aggregate Water absorption
    Particle density 50 kg
    Flakiness index
    Fines content
    LA Abrasion value

    Tensile test 500 mm


    Reinforcement
    Bend test 300 mm

    Water Full range of tests 5 litres


    QCS 2014 Section 05: Concrete Page 6
    Part 01: General

    Table 1.2
    Minimum Testing Equipment for Each Site*
    Minimum Number
    Test Equipment to be Provided
    Required
    Slump cone with base plate 1
    Slump test BS EN
    Compacting rod, circular cross-section 1
    12350-2
    and round ends 1
    or
    Remixing container, 300 mm ruler, 1
    GSO ISO 1920-2
    moist cloth 1
    or
    Scoop and shovel
    ASTM C143
    Timer
    Cube making 100 or 150 mm cubical or cylindrical 6
    1
    BS EN 12390-1 moulds
    and Compacting rod or bar Set of tools for 1

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    BS EN 12350-1:2000 assembling and stripping moulds

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    or Remixing container 1

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    GSO ISO 1920-1 Trowel, Scoop, Shovel and Mallet -
    and Mould release agent in closed -
    GSO ISO 1920-3 container with brush 1
    or ASTM C31 and C39
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    Hessian or sacking, impervious sheet lot
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    Cube curing BS EN Maximum/minimum thermometer 1
    12390-2 Waterproof marking crayon/paint or
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    or equivalent 1
    GSO ISO 1920-3 Curing tank (in air conditioned room) 1
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    or ASTM C39 Supply of packing materials for sending


    cubes to commercial laboratory Lot
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    ASTM C1064 Concrete thermometer 1


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    1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate
    size is not greater than 20mm
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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 10: Curing

    10 CURING .................................................................................................................. 2
    10.1 GENERAL ............................................................................................................... 2
    10.1.1 Scope 2
    10.1.2 References 2
    10.1.3 Submittals 2
    10.1.4 Quality Assurance 2
    10.1.5 Storage 2
    10.2 CURING .................................................................................................................. 2
    10.2.1 General 2
    10.2.2 Water for Curing 3
    10.2.3 General Requirements 3
    10.2.4 Curing of Formed Surfaces 4

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    10.2.5 Curing of Unformed Surfaces 4

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    10.2.6 Moisture Curing 4
    10.2.7 Moisture Retaining Cover Curing 4

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    10.2.8 Liquid Membrane Curing 5
    10.2.9 Steam Curing 5
    10.2.10 Pavements and other slab on ground
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    10.2.11 Buildings, bridges, and other structures 5
    10.2.12 Mass concrete 6
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    QCS 2014 Section 05: Concrete Page 2
    Part 10: Curing

    10 CURING

    10.1 GENERAL

    10.1.1 Scope

    1 This part covers the requirements for the curing of concrete.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, ............ General
    Part 4, ............ Water
    Part 6, ............ Property Requirements

    .
    Part 15, ........... Hot Weather Concreting

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    Part 16, ........... Miscellaneous.

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    10.1.2 References
    AASHTO M 148.74, ...Liquid Membrane Curing
    ACI 308 ..................... Guide to Concrete Curing
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    ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing
    Concrete
    BS 7542,..................... Method of test for curing compounds for concrete.
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    ISO 9001: 2008 Quality management systems -- Requirements


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    10.1.3 Submittals
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    1 The Contractor shall submit to the Engineer the proposed method of curing for approval.
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    10.1.4 Quality Assurance


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    1 The Contractor shall submit to the Engineer for approval the details of proposed curing
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    media, if any. Details shall include chemical tests for the product in accordance with
    et

    BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.
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    10.1.5 Storage

    1 Chemical curing compounds shall be stored in accordance with manufacturer's


    recommendations.

    10.2 CURING

    10.2.1 General

    1 The Contractor shall ensure that curing is provided for 24 hours per day including holidays
    and that all related necessary plant and labour resources are also available.

    2 Special attention shall be given to the curing of vertical and overhanging surfaces to ensure
    satisfactory curing.
    QCS 2014 Section 05: Concrete Page 3
    Part 10: Curing

    3 The Contractor shall adopt curing measures that preclude the possibility of thermal shock to
    the concrete during curing. This may be achieved by ensuring that the temperature of the
    water used for curing does not differ from that of the concrete by more than 15 C.

    4 Curing shall continue for at least 7 days and until it attains an in-place compressive strength
    of the concrete of at least 70% of the specified compressive or flexural strength, whichever
    period is longer. Curing shall not stop unless otherwise approved by the Engineer.

    5 When low W/cm is used, the concrete shall be preferably cured by water.

    10.2.2 Water for Curing

    1 Water used for any curing purposes shall conform to the requirements of Part 4 of this
    Section.

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    10.2.3 General Requirements

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    1 Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive
    drying out.

    2
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    All concrete shall be cured for a period of time required to obtain the full specified strength,
    but not less than seven consecutive days. The method of curing shall be by water for the first
    qa
    seven days and by water or membrane until the concrete has reached the full specified
    strength.
    as

    3 For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative
    se

    environments, or both, the curing shall start at early anytime between placement and final
    finishing of the concrete. The curing shall be by reducing the moisture loss from surface
    er

    using fogging systems and the use of evaporation reducers such as monomolecular water
    curing compound.
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    4 Exposed surfaces shall be protected from air blown contamination until 28 d after the
    concrete is placed.
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    5 The method of curing shall ensure that sufficient moisture is present to complete the
    et

    hydration of the cement, and shall be to the approval of the Engineer. The method of curing
    shall not:
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    (a) disfigure permanently exposed surfaces


    (b) affect bonding of subsequent coatings
    (c) increase the temperature of the concrete.

    6 During the curing period, exposed concrete surface shall be protected from the direct rays of
    the sun.

    7 When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water
    is present on the surface of the concrete.

    8 The applied film of the liquid membrane shall be continuous and protected from rain and any
    damages for at least 14 days.
    QCS 2014 Section 05: Concrete Page 4
    Part 10: Curing

    10.2.4 Curing of Formed Surfaces

    1 Formed surfaces, including the underside of beams, girders, supported slabs and the like, by
    moist curing with the forms in place for the full curing period, or until the forms are removed.

    2 When the forms are stripped, curing shall continue by any approved method.

    3 When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In
    such cases the concrete surface shall be prepared prior to the application of the membrane
    as recommended by the manufacturer.

    4 Water curing is not required when liquid membrane is used.

    10.2.5 Curing of Unformed Surfaces

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    1 Unformed surfaces shall be protected as soon as possible after the concrete has been

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    placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material

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    shall be placed on the concrete surface and shall be kept wet for the required period. The
    hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of
    water. Alternatively a curing method approved by the Engineer may be used.

    2 ta
    Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams
    qa
    shall be water cured and covered with wet hessian for the required curing period.
    as

    10.2.6 Moisture Curing

    1 Moisture curing shall be performed by :


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    (a) covering the surface of the concrete with water and keeping it continuously wet
    er

    (b) continuous use of fine fog water sprays


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    (c) covering the surface with a saturated absorptive cover and keeping it continuously
    wet.
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    (d) Burlap, cotton mats, and other absorbent materials can be used to hold water on
    it

    horizontal or vertical surfaces.


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    (e) Wet straw or hay can be used for wet-curing small areas, but there is the danger that
    m

    wind might displace it unless it is held down with screen wire, burlap, or other means

    2 Where method (a) is employed, the bunds used shall not be made from fill from excavations
    or any other areas where there is the possibility of chloride contamination.

    10.2.7 Moisture Retaining Cover Curing

    1 The concrete surface shall be covered with a suitable absorptive covering, such as wet
    hessian.

    2 The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

    3 The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

    4 Any penetrations or tear in the covering shall be shall be repaired with the same material and
    waterproof tape.
    QCS 2014 Section 05: Concrete Page 5
    Part 10: Curing

    10.2.8 Liquid Membrane Curing

    1 Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM
    C 309 or C1315 when tested at the rate of coverage use on the job.

    2 ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid
    membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for
    determining the efficiency of liquid membrane-forming compounds.

    3 Membrane forming curing compounds shall be applied in accordance with the manufacturer's
    recommendations immediately after any water sheen which may develop after finishing has
    disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

    4 Membrane forming curing compounds shall not be used on surfaces against which additional
    concrete or other material is to be bonded unless:

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    (a) it is proven that the curing compound will not prevent bond, or

    rw
    (b) positive measures are taken to remove it completely from those areas which are to
    receive bonded applications
    (c) on fair faced concrete surfaces.
    ta
    qa
    10.2.9 Steam Curing

    1 An enclosure shall be formed around the concrete using tarpaulin or other suitable means.
    as

    2 Application of steam shall not be commenced until at least 2 h after final placement of
    se

    concrete.
    er

    3 Steam shall be applied at a temperature between 65 C and 80 C.


    ov

    4 Excessive rates of heating and cooling shall be prevented during steam curing and
    temperatures in the enclosure shall not be allowed to increase or decrease by more than
    22 C per hour.
    it o

    5 The maximum steam temperature shall be maintained in the enclosure until concrete has
    et

    reached its specified strength.


    m

    10.2.10 Pavements and other slab on ground

    1 Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective
    measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be
    initiated immediately to reduce evaporation.

    2 Mats used for curing can either be left in place and kept saturated for completion of the
    curing, or can be subsequently replaced by a liquid membrane-forming curing compound,
    plastic sheeting, reinforced paper, straw, or water

    10.2.11 Buildings, bridges, and other structures

    1 Additional curing shall be provided after the removal of forms


    QCS 2014 Section 05: Concrete Page 6
    Part 10: Curing

    2 After the concrete has hardened and while the forms are still in place on vertical and other
    formed surfaces, form ties may be loosened when damage to the concrete will not occur and
    water applied to run down on the inside of the form to keep the concrete wet.

    3 Care shall be taken to prevent thermal shock and cracks when using water that is
    significantly cooler than the concrete surface. Curing water should not be more than about
    o
    11 C cooler than the concrete.

    4 Immediately following form removal, the surfaces shall be kept continuously wet by a water
    spray or water-saturated fabric or until the membrane-forming curing compound is applied.
    Curing

    10.2.12 Mass concrete

    1 Mass concrete is often cured with water for the additional cooling benefit in warm weather;

    l .
    however, this can be counterproductive when the temperature gradient between the warmer

    .l.
    interior and the cooler surface generates stress in the concrete.

    rw
    2 Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously
    wet by water spraying, wet sand, or water saturated fabrics.

    3 ta
    For vertical and other formed surfaces, after the concrete has hardened and the forms are
    qa
    still in place, the form ties may be loosened and water supplied to run down the inside of the
    form to keep the concrete wet
    as

    4 Care shall be taken to prevent thermal shock and cracks when using water that is
    se

    significantly cooler than the concrete surface. Curing water should not be more than about
    o
    11 C cooler than the concrete.
    er

    5 Curing shall start as soon as the concrete has hardened sufficiently to prevent surface
    ov

    damage.

    6 For unreinforced massive sections not containing ground granulated blast-furnace slag or
    o

    pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated
    it

    blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall
    et

    be not less than 3 weeks.


    m

    7 For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until
    70% of the specified compressive strength is obtained, if strength is the key concrete
    performance criterion. For construction joints, curing shall be continued until resumption of
    concrete placement or until the required curing period is completed.

    8 Curing shall not stop until favourable differential temperature is attained and at the approval
    of the Engineer.

    9 For mass concrete, thermocouples shall be used to monitor the temperature differential of
    the concrete.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 11: Reinforcement

    11 REINFORCEMENT ................................................................................................. 2
    11.1 GENERAL ............................................................................................................... 2
    11.1.1 Scope 2
    11.1.2 References 2
    11.1.3 Submittals 3
    11.1.4 Quality Assurance 3
    11.1.5 Delivery Storage and Handling 3
    11.2 REINFORCING MATERIALS .................................................................................. 4
    11.2.1 Reinforcing Bars 4
    11.2.2 Welded Steel Wire Fabric 4
    11.2.3 Tie Wire 5
    11.3 INSPECTION, SAMPLING AND TESTING.............................................................. 5

    .
    11.3.2 Sampling 5

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    .l.
    11.3.3 Testing 6

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    11.4 CUTTING AND BENDING OF REINFORCEMENT ................................................. 6
    11.5 FIXING OF REINFORCEMENT ............................................................................... 6
    11.5.1
    11.5.2
    General
    Welding ta 6
    7
    qa
    11.5.3 Mechanical Splices 8
    11.5.4 Bundling and Splicing of Bundled Bars 8
    as

    11.5.5 Examination 8
    11.5.6 Electrolytic Action 8
    se

    11.5.7 Cover 8
    11.5.8 Reinforcement 8
    er

    11.5.9 Forms and Linings 9


    ov

    11.5.10 Tanking 9
    11.5.11 Adjustment and Cleaning 9
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    11.6 PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9


    it

    11.6.2 Epoxy Coated Reinforcing Bars 9


    et

    11.6.3 Handling of Epoxy Coated Reinforcement 11


    11.6.4 Testing of Epoxy Coated Reinforcement 11
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 11: Reinforcement

    11 REINFORCEMENT

    11.1 GENERAL

    11.1.1 Scope

    1 This Part includes tension, compression, and temperature reinforcing steel, including welded
    wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and
    placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric,
    ties, and supports.

    2 Related Sections and Parts are as follows:


    This Section
    Part 16 ............. Miscellaneous

    l .
    Part 17 ............. Structural Precast Concrete

    .l.
    11.1.2 References

    rw
    ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for
    Prestressed Concrete

    ta
    ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for
    qa
    Concrete Reinforcement
    ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete
    Reinforcement
    as

    ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or


    Low-Relaxation for Prestressed Concrete Railroad Ties
    se

    ASTM A882/A882M- ..Standard Specification for Filled Epoxy-Coated Seven-Wire


    Prestressing Steel Strand
    er

    ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars
    for Concrete Reinforcement
    ov

    ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel
    Wire and Welded Wire for Concrete Reinforcement
    o

    ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for
    it

    Concrete Reinforcement:
    et

    BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete
    m

    BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of
    concrete
    BS 4483: 2005............Steel fabric for the reinforcement of concrete
    BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing
    of concrete.
    BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of
    steel reinforcement for concrete

    EN 1011, ....................Welding. Recommendation for welding of metallic materials


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

    ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete


    ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the
    reinforcement of concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 11: Reinforcement

    ISO 3766 ...................Construction drawings -- Simplified representation of concrete


    reinforcement
    ISO 9000, ..................Quality management systems. Fundamentals and vocabulary

    QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars
    QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars
    QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric

    11.1.3 Submittals

    1 Product data including the manufacturers specification and installation instructions for
    proprietary materials and reinforcement accessories shall be provided.

    2 The Contractor shall submit the manufacturers records of chemical and physical properties

    .
    of each batch of billet steel bars and a certificate that the respective material furnished meets

    l
    .l.
    the requirements for the steel reinforcement specified. The manufacturers records shall
    include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

    rw
    3 Three copies of the steel test report shall be furnished with each consignment of steel

    ta
    reinforcement. The steel shall be tagged and cross-referenced with mill certificates.
    qa
    11.1.4 Quality Assurance

    1 The Contractor shall submit to the Engineer for source approval details of the proposed
    as

    source of supply of the reinforcement. Details shall include chemical and physical tests for
    the past six months production and any independent test results for this period. Details of
    se

    quality assurance procedures, including ISO 9000 certificate if held, shall also be given.
    er

    2 The Contractor shall furnish the Engineer with a certificate of compliance for each shipment
    of epoxy coated bars. The certificate of compliance shall state that representative samples of
    ov

    the epoxy coated bars have been tested and that the test results comply with the
    requirements herein specified. Test results shall be retained by the Contractor for seven
    o

    years. A complete set of test results shall also be handed to the client at the completion of
    reinforcement works, and shall be made available to the Engineer upon request.
    it
    et

    11.1.5 Delivery Storage and Handling


    m

    1 On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show
    the manufacturers test number and lot number and other applicable data that will identify the
    material with the certificate issued for that lot of steel. The fabricator shall furnish three
    copies of a certification which shows the batch number or numbers from which each size of
    bar in the shipment was fabricated.

    2 Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the


    ground surface to prevent damage and accumulation of dirt, rust and other deleterious
    matter. Storage facilities shall be such as to permit easy access for inspection and
    identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark
    reference.
    QCS 2014 Section 05: Concrete Page 4
    Part 11: Reinforcement

    3 The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock
    loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free
    from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may
    impair the bond between the concrete and the reinforcement. The reinforcement shall be
    covered to ensure protection from wind blown dust, condensation and other deleterious
    materials.

    11.2 REINFORCING MATERIALS

    11.2.1 Reinforcing Bars

    1 Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply
    with the requirements of:

    (i) QS ISO 6935 with minimum grade of B500 MPa or

    l .
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    (ii) BS 4449 with minimum grades of B500 MPa ; or..

    rw
    (iii) ASTM A615 / A615M with minimum grade of 75 [520MPa]; or
    (iv) Deformed and Plain, Low-carbon-Chromium-Steel Bars for Concrete

    (v)
    Reinforcement: ASTM A1035/ A1035M
    ta
    ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain
    qa
    Stainless Steel Wire and Welded Wire for Concrete Reinforcement
    (vi) ASTM A955/A955M-14 Standard Specification for Deformed and Plain
    as

    Stainless-Steel Bars for Concrete Reinforcement


    se

    (vii) Other types of reinforcement, as approved by Qatar Standards

    2 As per project design, other steel grades of less than B500MPa may be used only for stirrups
    er

    and secondary reinforcement of diameter of 10mm or less.


    ov

    3 If the steel has excessive surface rust, dust or other deleterious material then the steel shall
    be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of
    o

    the reinforcement or concrete. Dune sand shall not be used for the sandblasting of
    it

    reinforcement.
    et

    4 For extreme exposure class X5; protection measures such as epoxy coated bars; Low-
    m

    carbon-chromium-steel bars; or Stainless Steel may be considered.

    11.2.2 Welded Steel Wire Fabric

    1 Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483
    and shall be delivered to Site in flat mats.

    2 Welded intersections shall not be spaced more than:

    (a) 300 mm for plain round bars


    (b) 400 mm apart for deformed high yield bars in direction of calculated stress except
    when used as stirrups.
    QCS 2014 Section 05: Concrete Page 5
    Part 11: Reinforcement

    11.2.3 Tie Wire

    1 Tie wire shall conform to the requirements of BS 4482.

    2 1.6 mm black annealed mild steel shall be used for tie wire.

    3 No wires smaller than size D-4 shall be used.

    11.3 INSPECTION, SAMPLING AND TESTING

    1 Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

    2 The Contractor shall give 24 hour notice to the Engineer before closing forms or placing

    .
    concrete.

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    .l.
    3 The Engineer may instruct the Contractor to break out and remove completely all sections of

    rw
    the work already constructed under any of the following circumstances:

    (a) reinforcing steel sample under test fails to meet the specification requirements at any
    time
    ta
    qa
    (b) the Engineer considers that samples which were presented to him for test were not
    truly representative
    as

    (c) a previously rejected reinforcing steel has been used in the Works.
    se

    11.3.2 Sampling

    1 Representative samples of all reinforcing steel proposed for use in the Works must be
    er

    submitted by the Contractor, before work is commenced, to the Engineer for his written
    ov

    approval.

    2 Manufacturer's certificates stating clearly for each sample:


    it o

    (a) place of manufacture


    et

    (b) expected date and size of deliveries to site


    m

    (c) all relevant details of composition, manufacture, strengths and other quality of the
    steel.

    3 The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at
    the work site.

    4 Frequency of sampling and the method of quality control shall be in accordance with steel
    bars manufactured standard QS ISO 6935 or BS 4449 .

    5 Where epoxy coated steel is used, a sample of the coating material shall be supplied with
    each batch in an airtight container and identified by the batch number.

    6 Allow 14 days for Engineers review of samples.


    QCS 2014 Section 05: Concrete Page 6
    Part 11: Reinforcement

    11.3.3 Testing

    1 Tests shall be carried out when directed by the Engineer.

    2 Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

    3 The following information shall be provided with each delivery of reinforcement:

    (a) elastic limit


    (b) ultimate strength
    (c) stress/strain curve
    (d) cross-sectional area
    (e) deformation/bond characteristics of deformed bars.

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    4 The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or
    rebend tests at own cost, for each size of bar to be used in the concrete construction.

    rw
    5 Test results for each bar size shall be submitted to the Engineer three weeks before concrete
    work commences on Site.
    ta
    qa
    6 Full testing shall be required if the source of supply of reinforcement changes, in which case
    the cost of such extra testing will be borne by the Contractor.
    as

    7 When any test results do not conform to the relevant standard the reinforcement steel shall
    be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.
    se

    11.4 CUTTING AND BENDING OF REINFORCEMENT


    er

    1 Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and
    ov

    shall be done without the application of heat. Bends shall have a substantially constant
    curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply
    o

    2 Steel bars manufactured according to the approved ASTM standards shall be bent according
    it

    to the same standard.


    et
    m

    3 Reinforcement shall not be straightened or rebent without the approval of the Engineer. If
    permission is given to bend projecting reinforcement care shall be taken not to damage the
    concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or
    BS 8666.

    11.5 FIXING OF REINFORCEMENT

    11.5.1 General

    1 All reinforcement shall be securely and accurately fixed in positions shown on the Drawings
    to ensure that the reinforcement steel framework as a whole shall retain its shape. The
    framework shall be supported to retain its correct position in the forms during the process of
    placing and consolidating the concrete.

    2 The ends of all tying wires shall be turned into the main body of the concrete and not allowed
    to project towards the surface.
    QCS 2014 Section 05: Concrete Page 7
    Part 11: Reinforcement

    3 No part of the reinforcement shall be used to support access ways, working platform or for
    the conducting of an electric current.

    4 The Contractors specific attention is drawn to the following general requirements:

    (a) lapped joints shall be as indicated on the Drawings and/or in accordance with the
    requirements of EN 1992-1-1 or BS 8666
    (b) hooks shall be semicircular with a straight length of at least:
    (i) four bar diameters for mild steel
    (ii) six bar diameters for high yield steel.

    11.5.2 Welding

    1 Welding shall not be used unless authorised by the Engineer and recommended by the

    l .
    reinforcement manufacturer.

    .l.
    rw
    2 Where welding is approved it shall be executed under controlled conditions in a factory or
    workshop.

    3
    ta
    Welding shall not take place on site without the approval of the Engineer and unless suitable
    safeguards and techniques are employed and the types of steel employed have the required
    qa
    welding properties.
    as

    4 Welding if approved, may be used for:

    (a) fixing crossing or lapping reinforcement in position


    se

    (b) fixing bars to other steel members


    er

    (c) structural welds involving transfer of loads between reinforcement or between bars
    and other steel members.
    ov

    5 The length of run deposited in a single pass shall not exceed five times the bar diameter. If a
    longer welded length is required, the weld shall be divided into sections with the space
    o

    between runs made not less than five times the bar diameter.
    it
    et

    6 Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be
    m

    approved, subject to their satisfactory performance in trial joints.

    7 Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for
    lapped joints.

    8 Flash butt welding shall be executed with the correct combination of flashing, heating,
    upsetting and annealing, using only machines which automatically control this cycle of
    operations.

    9 Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement
    manufacturer.

    10 Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of
    principle reinforcement shall be staggered, unless otherwise approved. The distance
    between staggered joints shall be not less than the end anchorage length joints.

    11 Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.
    QCS 2014 Section 05: Concrete Page 8
    Part 11: Reinforcement

    11.5.3 Mechanical Splices

    1 Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and
    where indicated on the Drawings.

    2 Details of mechanical splices shall be submitted to the Engineer for approval.

    11.5.4 Bundling and Splicing of Bundled Bars

    1 Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

    2 Splicing, except where indicated on the Drawings or approved shop drawings, will not be
    permitted without the approval of the Engineer.

    11.5.5 Examination

    l .
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    1 The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of

    rw
    reinforcement in order to facilitate the inspection of formwork.

    2 The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

    11.5.6 Electrolytic Action ta


    qa
    1 Reinforcement shall not be fixed or placed in contact with non-ferrous metals.
    as

    11.5.7 Cover
    se

    1 Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer
    pieces.
    er

    2 The cover shall not be less than given in Section 5 Part 6.


    ov

    3 Spacers, chairs and other supports shall be provided as necessary to maintain the
    o

    reinforcement in its correct position.


    it
    et

    4 In a member where the nominal cover is dimensioned to the links, spacers between the links
    and formwork shall be the same dimension as the nominal cover.
    m

    5 Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in
    diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars
    are detailed.

    6 Spacers, chairs and other supports shall be made of concrete, plastic or other material to the
    approval of the Engineer. Where supports are made of concrete they shall have at least the
    same cube strength as the concrete in the host member.

    11.5.8 Reinforcement

    1 Placing of all reinforcement steel bars will be checked by the Engineer and in no case is
    concrete to be placed around any reinforcement steel that has not been approved by the
    Engineer. Insertion of bars into or the removal of bars from concrete already placed will not
    be permitted.
    QCS 2014 Section 05: Concrete Page 9
    Part 11: Reinforcement

    2 Reinforcement steel temporarily left projecting from the concrete at the joints shall not be
    bent without the prior approval of the Engineer.

    11.5.9 Forms and Linings

    1 Damage to forms and linings shall be avoided.

    11.5.10 Tanking

    1 Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

    11.5.11 Adjustment and Cleaning

    1 Check position of reinforcement before and during placing concrete:

    .
    (a) pay particular attention to the position of top reinforcement in cantilever sections

    l
    .l.
    (b) ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill

    rw
    scale, oil and other substances which may adversely affect reinforcement, concrete, or
    the bond between the two.

    2
    ta
    Protect projecting reinforcement from the weather where rust staining of exposed concrete
    surfaces may occur.
    qa
    3 At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and
    as

    freed from all mud, oil or any other coatings that might destroy or reduce the bond:

    (a) clean all set or partially set concrete which may have been deposited thereon during
    se

    the placing of a previous lift of concrete


    er

    (b) all uncoated rust bars shall be again sand blasted and pressure washed.
    ov

    4 Immediately before concrete placing the reinforcing steel shall be washed thoroughly with
    high pressure potable water jets to remove any deposited salts.
    o

    11.6 PROTECTIVE COATINGS TO REINFORCEMENT


    it
    et

    1 All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.
    m

    11.6.2 Epoxy Coated Reinforcing Bars

    1 Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting,
    rust, grease, oil and other surface defects detrimental to proper coating.

    2 The surface shall be prepared in accordance with ISO 14654.

    3 Coating shall be applied to the cleaned surface as soon as possible after cleaning and before
    any visible oxidation to the surface occurs.

    4 Reinforcing steel shall not have surface defects that would be detrimental to coating.

    5 Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for
    coating of reinforcing bars and as follows:

    (a) epoxy resin powders which do not meet the above requirements must be tested by an
    approved independent testing laboratory and accepted by the Engineer before use
    QCS 2014 Section 05: Concrete Page 10
    Part 11: Reinforcement

    (b) only fusion bonded epoxy-coated reinforcing steel will be accepted


    (c) no other means of epoxy coating will be approved.

    6 Patching material shall be:

    (a) furnished by the epoxy coating manufacturer


    (b) compatible with the coating
    (c) inert in concrete
    (d) suitable for repairs to the coated reinforcing bars to be made by the coating applicator
    and the Contractor at the project site.

    7 Fabrication shall be performed before coating except as hereinafter specified for bent bars
    and straight bars less than 7.6 m long.

    l.
    8 Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that

    .l.
    satisfactory results can be obtained by coating before bending.

    rw
    9 Any visible cracks in the coating on the outside of the bend or damage to coating resulting in
    debonding of the coating after bending shall be rejected.

    10 ta
    Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:
    qa
    (a) end damage to coating does not extend more than 12 mm back
    as

    (b) cut end is patched before any visible oxidation appears.


    se

    11 Flame cutting will not be permitted.

    12 Epoxy coating shall be checked visually after cure for continuity of coating and shall be free
    er

    from holes, contamination, cracks and damaged areas.


    ov

    13 There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm
    of the epoxy coated bar.
    it o

    14 A holiday detector shall be used in accordance with the manufacturer's instruction to check
    et

    the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or
    its approved equivalent shall be used.
    m

    15 Patching of holidays is not required if there are less than three holidays per 300 mm length.
    Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced
    as directed by the Engineer.

    16 Epoxy coating film shall be cured and/or post cured to a fully cured condition. A
    representative proportion of each production lot shall be checked by the epoxy coating
    applicator, using the method most effective for measuring cure to ensure that the entire
    production lot of epoxy coating is supplied in the fully cured condition.

    17 Contractor shall repair all coating damaged by fixtures used to handle or support the bars in
    the coating process as follows:

    (a) patching shall be done as soon as possible and before visible oxidation occurs
    (b) excessive patching from other causes will not be permitted
    QCS 2014 Section 05: Concrete Page 11
    Part 11: Reinforcement

    (c) satisfactory correction shall consist of proper adjustment of process, and rerunning
    the bars through the plant.

    18 The Engineer reserves the right for access to the epoxy coating applicators plant to witness
    epoxy coating processes for project work and to obtain specimens from test bars for any
    testing desired.

    19 All chairs, tie wires and other devices used in connecting, supporting, securing or fastening
    epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

    20 Before the reinforcement is lowered into place and before placement of the concrete, the
    coated bars shall be inspected by the Engineer for damage to the epoxy coating.

    21 Sheared ends of bars and other areas requiring limited repair due to scars and minor defects
    shall be repaired, using the specified patching or repair materials.

    l .
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    11.6.3 Handling of Epoxy Coated Reinforcement

    rw
    1 Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars
    or, where used, the epoxy coating.

    2 ta
    Bars, or where used epoxy coating, damaged in handling or other operations shall be
    qa
    satisfactorily repaired at no additional cost to the Employer.

    3 Where epoxy coated bars are used all handling systems shall have plastic mandrel and
    as

    padded contact areas wherever possible.


    se

    4 Where epoxy coated bars are used all bundling bands shall be padded.
    er

    5 All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to
    prevent bar to bar abrasion from sags in the bar bundle.
    ov

    6 Bars or bundles shall not be dropped or dragged.


    o

    7 During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not
    it

    damaged by the pokers.


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    m

    11.6.4 Testing of Epoxy Coated Reinforcement

    1 Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each
    production lot.

    2 At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be
    furnished as test bars.

    3 Test bars may be in one length or multiple lengths as required to have one test bar of each
    size with each production lot.

    4 The production epoxy coated test bars shall be evaluated by bending 120 (after rebound)
    around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.
    QCS 2014 Section 05: Concrete Page 12
    Part 11: Reinforcement

    Table 11.1
    Mandrel Diameter for Bar Diameter for
    Evaluation Test of Epoxy Coated Test Bars
    Bar Diameter Diameter of Mandrel
    (mm) (mm)

    10 79
    12 95
    13 103
    14 111
    16 127
    18 143
    20 159
    22 175

    .
    24 191

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    25 198
    26 206

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    28 222
    30 238
    32
    34 ta 254
    270
    qa
    36 286
    as

    5 Bend shall be made at a uniform rate and may take up to one minute to complete.
    se

    6 Bend test shall be conducted at a room temperature of between 20 C and 30 C after the
    er

    specimen has been exposed to room temperature for a sufficient time to ensure that it has
    reached thermal equilibrium.
    ov

    7 No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the
    bent bar.
    it o
    et

    END OF PART
    m
    QCS 2014 Section 05: Concrete Page 1
    Part 12: Joints

    12 JOINTS.................................................................................................................... 2
    12.1 GENERAL ............................................................................................................... 2
    12.1.1 Scope 2
    12.1.2 References 2
    12.1.3 Submittals 2
    12.1.4 Quality Assurance 3
    12.1.5 Definitions 3
    12.2 CONSTRUCTION JOINTS ...................................................................................... 4
    12.2.1 General 4
    12.2.2 Construction Joints in Water Retaining Structures 4
    12.3 MOVEMENT JOINTS .............................................................................................. 5
    12.3.1 General 5

    .
    12.3.2 Joint Filler 6

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    12.3.3 Joint Sealants 6

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    12.4 SLIP BEARINGS ..................................................................................................... 7
    12.4.1 General 7
    12.5
    12.5.1 General ta
    WATERSTOPS ....................................................................................................... 7
    7
    qa
    12.5.2 Waterstops 7
    12.5.3 Butyl Rubber Waterstops 8
    as

    12.5.4 Water Swelling Gaskets 8


    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 12: Joints

    12 JOINTS

    12.1 GENERAL

    12.1.1 Scope

    1 This part deals with movement and construction joints, slip bearings, waterstops and
    associated sealants and filler materials.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1 ............... General
    Part 10, ............ Curing

    l .
    Part 15, ............ Hot Weather Concreting

    .l.
    Part 16, ............ Miscellaneous

    rw
    12.1.2 References
    ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for

    ta
    Concrete Paving and Structural Construction (Non-extruding and
    qa
    Resilient Bituminous Types)
    ASTM D2240 ..............Standard Test Method for Rubber PropertyDurometer Hardness
    ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From
    as

    Olefin Polymers
    se

    BS 903........................Physical testing of rubber


    er

    BS 2571......................General purpose flexible PVC compounds for moulding and extrusion


    BS 2782,.....................Methods of testing plastics
    ov

    BS 6093,.....................Design of joints and joining in building construction


    BS 7164,.....................Chemical tests for raw and vulcanized rubber
    o

    BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and


    it

    containing structures
    et

    BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test


    m

    CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop

    ISO 9001 ....................Quality management systems. Requirements

    12.1.3 Submittals

    1 The Contractor shall submit for approval by the Engineer as soon as practicable after
    acceptance of his Tender and not less than three weeks before commencement of
    concreting, drawings showing his proposals for the position of construction joints having due
    regard to any that may be shown on the Contract Drawings.
    QCS 2014 Section 05: Concrete Page 3
    Part 12: Joints

    2 For slide bearings the Contractor shall provide at least three samples of the proposed
    material, together with the manufacturer's technical specifications and recommendations in
    respect of application and performance.

    3 For slip joints the Contractor shall provide at least three samples of materials proposed,
    together with manufacturer's technical specifications and recommendations in respect of
    application and performance.

    4 For waterstops the Contractor shall provide at least three samples of proposed types,
    including prefabricated joints and junctions, if applicable. If joints are to be made up on site,
    provide worked samples, including samples for each make of waterstop, where samples
    from different manufacturers are provided.

    5 The Contractor must supply a certificate of compliance for the joint sealant, stating that it
    meets the requirements of the specification. The Contractor shall also supply the

    l .
    Manufacturers technical and installation data for the proposed material. The Contractor shall

    .l.
    provide details of previous installations of the product, with the client name, structure name,

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    type of joint and value of contract.

    6 The Contractor shall prepare shop drawings that show the layout of the waterstops, specials
    and joints.
    ta
    qa
    12.1.4 Quality Assurance
    as

    1 The joint sealant, including primers and debonding materials shall be compatible with each
    other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality
    se

    Assurance Scheme.
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    12.1.5 Definitions
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    1 Construction Joint: The surface where two successive placements of concrete meet, across
    which it is desirable to develop and maintain bond between the two concrete placements, and
    through which any reinforcement which may be present is not interrupted.
    it o

    2 Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a


    et

    weakened plane and regulate the location of cracking resulting from the dimensional change
    of different parts of the structure. (See also Isolation Joint.)
    m

    3 Expansion Joint: A separation between adjoining parts of a concrete structure which is


    provided to allow small relative movements such as those caused by thermal changes to
    occur independently.

    4 Isolation Joint: A separation between adjoining parts of a concrete structure provided to


    isolate and element and thus allow independent movement.

    5 Joints Fillers: Materials that are used to fill space within movement joints during construction.
    They may provide support to a sealant applied subsequently.
    QCS 2014 Section 05: Concrete Page 4
    Part 12: Joints

    12.2 CONSTRUCTION JOINTS

    12.2.1 General

    1 Where construction joints are required in slabs or beams (designed by Direct Design Method
    DDM) they shall be located within the middle third of their spans, and at one-third to one-
    quarter of span in slabs and beams subject to a maximum spacing of approximately 9
    metres. Where slabs are supported by beams then the beams and slabs shall be constructed
    in one operation.

    2 In all cases vertical stop boards of a form to be approved by the Engineer shall be provided
    by at the end of each section of work which is to be concreted in one operation and the
    concrete shall be thoroughly compacted against these stop boards.

    .
    3 Where slabs, beams and walls incorporate construction joints, panels shall generally be

    l
    .l.
    constructed consecutively. Where this is not possible a gap not exceeding one metre shall be
    formed between adjacent panels. This gap shall not be concreted until a minimum interval of

    rw
    7 d has expired since the casting of the most recent panel.

    4 The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but

    ta
    in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with
    qa
    nominal reinforcement.

    5 Horizontal construction joints in walls will only be permitted when the wall is continuous with
    as

    the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls
    meeting the soffits of suspended members.
    se

    6 Construction joints in monolithic structures shall be aligned with each other whenever
    er

    practicable.
    ov

    7 Before placing new concrete against concrete which has already set the latter shall be
    treated to expose the aggregate over the full section and leave a sound irregular surface.
    This shall be done while the concrete is still fresh by means of water spray and light brushing
    o

    or other means approved by the Engineer.


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    et

    8 Immediately before the new concrete is placed all foreign matter shall be cleaned away and
    m

    the surface moistened.

    9 If during the course of the Contract it should become apparent that the Contractors methods
    of forming construction joints are not proving effective the Engineer may order the Contractor
    to execute at the Contractors expense such preventative measures as the Engineer may
    consider necessary to ensure the watertightness of the construction joints in further work.

    12.2.2 Construction Joints in Water Retaining Structures

    1 The floor may be designed as fully restrained against shrinkage and thermal contraction and
    should be cast directly onto the blinding concrete.

    2 In large structures, the floor shall be designed as a series of continuous strips with transverse
    induced contraction joints provided to ensure that cracking occurs in predetermined
    positions. Longitudinal joints between the strips should form contraction joints.
    QCS 2014 Section 05: Concrete Page 5
    Part 12: Joints

    3 Waterstops shall be incorporated into construction joints, crack induced joints, contraction
    joints and expansion joints in water retaining structures. The Contractor shall ensure that all
    such joints are watertight and any joints which may leak or weep shall be rectified by the
    Contractor to the Engineers satisfaction.

    4 The spacing of construction joints, crack induced joints, contraction joints and expansion
    joints in water retaining structures shall be shown on the design drawings.

    5 Where the positions or type of joints are not indicated on the drawings, the spacing of
    construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

    6 Where the positions or type of joints are not indicated on the drawings in the ground floor
    slab, construction joints, crack induced joints, contraction joints and expansion joints shall be
    incorporated into the works as appropriate. for slabs on grade, construction joints or crack
    induced joints should be provided at areas where differences in subgrade and slab support

    l .
    may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the

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    width of the building. Within each strip for both directions, crack induced joints shall be

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    provided at areas where cracks are expected and not more than 5.0 metre spacing, and
    construction or contraction joints shall be provided at not more than 15.0m spacing.

    7
    ta
    Construction or contraction joints shall be provided between adjacent strips.
    qa
    8 Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The
    waterstop should be made of a high quality material, which must retain its resilience through
    as

    the service life of the structure for the double function of movement and sealing. The surface
    of waterstops should be carefully rounded to ensure tightness of the joint even under heavy
    se

    water pressure. To ensure a good tightness with or without movement of the joints, the
    waterstop should be provided with anchor parts. The cross-section of the waterstops should
    er

    be determined in accordance with the presumed maximum water pressure and joint
    movements. The complete works of fixed and welded connections must be carried out
    ov

    strictly in accordance with the manufacturers instructions.

    9 Engineers acceptance shall be obtained by the Contractor, prior to start of work, on the
    o

    casting sequence and the layout of joints.


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    et

    12.3 MOVEMENT JOINTS


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    12.3.1 General

    1 Movement joints for expansion and contraction shall be constructed in accordance with the
    details and to the dimension shown on the Drawings or where otherwise ordered by the
    Engineer and shall be formed of the elements specified.

    2 Movement Joints in Water Retaining Structures shall be in accordance with the details and to
    the dimension shown on the Drawings and EN 1992-3.

    3 The Contractor shall pay particular attention to the effects of climatic extremes on any
    material which he may desire to use on any movement joint and shall submit for approval by
    the Engineer his proposals for the proper storage, handling and use of the said materials
    having due regard for any recommendations made by the manufacturer in this connection.
    QCS 2014 Section 05: Concrete Page 6
    Part 12: Joints

    12.3.2 Joint Filler

    1 Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if
    they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or
    equivalent if they are polymer foam type.

    2 The joint filler shall be fixed to the required dimensions of the joint cross-section and shall
    provide a firm base for the joint sealer.

    3 When required between two concrete surfaces as a resilient movement joint, the filler shall
    be an approved granulated cork bound with insoluble synthetic resin.

    4 When required between blockwork and concrete as a low density movement joint filler or for
    building details it shall be an approved bitumen impregnated fibreboard or preformed closed
    cell polyethylene.

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    12.3.3 Joint Sealants

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    1 All joints to be sealed shall be formed and the groove grit blasted to remove all traces of
    deleterious materials such as form oil or curing compounds and also to remove any surface

    ta
    laitance from the sides of the joint. The joint shall be dry prior the application of priming.
    Where the use of grit blasting is not possible the Contractor may propose alternative
    qa
    methods subject to the approval of the Engineer.
    as

    2 The back of the joint shall receive a debonding tape or polyethylene foam backer cord in
    order to provide the correct depth to width ratio and prevent three sided adhesion.
    se

    3 The areas adjacent to the joint shall be protected using masking tape.
    er

    4 The sides of the joint shall be primed with the relevant primer as recommended by the
    ov

    sealant manufacturer and the sealant material applied in accordance with the manufacturers
    instructions.
    o

    5 The sealant material shall be a non-biodegradable multicomponent pitch polyurethane


    it

    elastomeric joint sealant, carefully selected as appropriate for the specific climatic and
    et

    environmental exposure conditions expected. Alternative types of sealant will be considered,


    including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the
    m

    specification and the approval of the Engineer.

    6 Where the joint sealant is to be in contact with a protective coating the Contractor shall
    satisfy the Engineer that the sealant and protective coating are compatible

    7 Sealants shall exhibit the following properties:

    (a) Movement accommodation factor 25 %


    (b) Shore A hardness 20 - 25
    (c) Solids content 100 %
    o o
    (d) Service temperature range 0 C to 90 C
    (e) Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis
    (f) Width to depth ratio 2:1
    QCS 2014 Section 05: Concrete Page 7
    Part 12: Joints

    8 Where shown on the Drawings sealants shall also be suitable for use with potable water.

    9 All surface preparation, priming, mixing and application shall be carried out in strict
    accordance with the manufacturers instructions.

    10 The sealant shall have a proven track record of no less than ten years under similar local
    conditions.

    12.4 SLIP BEARINGS

    12.4.1 General

    1 Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

    2 They shall be extruded from specially formulated polyethylene to form a durable lamina

    l .
    resistant to sewage, mineral acids and alkalis, solvents and weathering.

    .l.
    rw
    3 Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with
    a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall
    be clean and free from deleterious materials such as form oil or curing compounds and

    ta
    surface laitance. The surface shall be level and even along the full length of the joint
    qa
    4 The applied loads for slip bearings shall not exceed 0.7 MPa.
    as

    5 Operating temperatures shall be up to 80 C


    se

    6 The coefficient of friction shall not exceed 0.15


    er

    12.5 WATERSTOPS
    ov

    12.5.1 General

    1 Waterstops and associated materials shall be by a manufacturer with a minimum of ten years
    o

    experience in the field of engineering waterproof products.


    it
    et

    2 PVC waterstops shall be suitable for storage, handling, installation and service within a range
    of 15 C to 65 C.
    m

    12.5.2 Waterstops

    1 The waterstop shall be a high performance system forming a continuous network as shown
    on the Drawings.

    2 Site jointing is to be limited to butt joints and shall be performed strictly in accordance with
    the manufacturers instructions.

    3 Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web
    sections.

    4 Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The
    water bar used at the location of expansion joints shall have a bulb in the centre to
    accommodate the movements.
    QCS 2014 Section 05: Concrete Page 8
    Part 12: Joints

    5 Waterstops shall have a minimum thickness of 3 mm.

    6 The minimum test performance data for PVC waterstops shall be as follows:
    Tensile strength >12 MPa
    Elongation at break 300 %
    Hardness Shore A 80 to 90
    7 The materials shall be tested in accordance with BS 2571 or BS 2782 or CRDC572 or
    ASTM D2240.

    12.5.3 Butyl Rubber Waterstops

    1 Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in
    accordance with BS 903.

    .
    Table 12.1

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    Properties Requirements of Butyl Rubber Waterstops

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    BS 903 Property Requirements

    ta
    3
    Part A1 Density 1100 kg/m ( 5 %)
    Part A26 Handness 60-70 IRHD
    qa
    2
    Part A2 Tensile Strength Not less than 17.5 N/mm
    Part A2 Elongation at break point Not less than 450 %
    as

    Part A/6 Water Absosption (48 hours immersion) Not exceeding 5 %


    se

    2 Butyl rubber waterstops shall be suitable for storage, handling, installation and service within
    a temperature of 0 C to 40 C
    er

    12.5.4 Water Swelling Gaskets


    ov

    1 Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer
    modified chloroprene rubber strips. The rubber strips shall conform to the following properties
    o

    as applicable:
    it
    et

    (a) Water pressure resistance : 5 Bar (50 m)


    m

    (b) Expansion in contact with water : 2 x original SRE


    (c) : Reversible
    (d) Application Temperatures : - 30 to + 70 C

    2 The selected rubber strips shall be available for three exposures:

    (a) Fresh Water


    (b) Seawater
    (c) Chemicals (if the condition demands or upon the Engineers request)
    The supplier shall furnish references upon request of the Engineer.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 13: Inspection and Testing of Hardened Concrete

    13 INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2


    13.1 GENERAL ............................................................................................................... 2
    13.1.1 Scope 2
    13.1.2 References 2
    13.1.3 Submittals 2
    13.1.4 Quality Assurance 3
    13.1.5 Non-Compliance of Work 3
    13.1.6 General Fieldwork Requirements 4
    13.2 CONCRETE CORES ............................................................................................... 4
    13.2.1 General 4
    13.2.2 Drilling Cores 5
    13.2.3 Testing for Strength 6

    .
    13.2.4 Assessment of Strength 7

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    13.3 REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

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    13.4 ULTRASONIC PULSE MEASUREMENTS .............................................................. 8
    13.4.1 General 8
    13.4.2
    13.4.3
    Selection of Test Locations
    Execution of Tests ta 8
    8
    qa
    13.4.4 Estimated In-Situ Cube Strength 9
    13.5 RADIOGRAPHY OF CONCRETE ........................................................................... 9
    as

    13.6 SURFACE HARDNESS ........................................................................................... 9


    13.6.1 General 9
    se

    13.6.2 Method of Test 9


    13.6.3 Equipment 10
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    13.6.4 Reporting 10
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    13.7 CHEMICAL CONTENT .......................................................................................... 10


    13.7.1 Sampling 10
    o

    13.7.2 Laboratory Testing 11


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    et
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    QCS 2014 Section 05: Concrete Page 2
    Part 13: Inspection and Testing of Hardened Concrete

    13 INSPECTION AND TESTING OF HARDENED CONCRETE

    13.1 GENERAL

    13.1.1 Scope

    1 This Part of the specification covers the inspection, sampling and testing of hardened
    concrete.

    2 Related Section and Parts are as follows:

    This Section
    Part 6 ............... Property Requirements

    .
    13.1.2 References

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    1 The following standards are referred to in this part of the specification:

    rw
    ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength
    Results

    ta
    ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and
    qa
    Commentary
    ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and
    Sawed Beams of Concrete
    as

    ASTM C823 ................Standard Practice for Examination and Sampling of Hardened


    Concrete in Constructions
    se

    BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete


    er

    BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic


    covermeters
    ov

    BS EN 12350..............Testing fresh concrete


    BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and
    o

    testing in compression
    it

    BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number


    et

    BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force


    m

    BS EN 12504-4 ..........Determination of ultrasonic pulse velocity


    BS EN 13791..............Assessment of in-situ compressive strength in structures and precast
    concrete components
    GSO ISO 1920-6 ........ Testing of concrete part 6: sampling, preparing and testing of
    concrete core .

    13.1.3 Submittals

    1 The Contractor shall submit to the Engineer his quality assurance procedures for the
    particular parts of the testing work that will be carried out.

    2 The Contractor shall submit for the Engineers approval the curriculum vitae (CV) of the
    supervisor proposed for the work.
    QCS 2014 Section 05: Concrete Page 3
    Part 13: Inspection and Testing of Hardened Concrete

    3 The Contractor shall through testing agency prepare a factual report that identifies the test
    methods used and the test results. The report shall also identify any unusual results or
    pertinent information relating to the testing. The report shall be presented in hard and
    electronic copies.

    4 For each of the test results the Contractor shall identify the precision or repeatability of the
    particular sampling and testing method. This shall be as given from experience of the
    particular test by the laboratory or as expected from information in the particular test
    standard.

    5 In-place tests will be valid only if the tests have been conducted using properly calibrated
    equipment in accordance with recognized standard procedures and acceptable correlation
    between test results and concrete compressive strength has been established and is
    submitted.

    l .
    6 Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete,

    .l.
    but they may be used to evaluate concrete when the standard-cured strengths fail to meet

    rw
    the specified strength criteria

    13.1.4 Quality Assurance

    1 ta
    All field and laboratory testing of concrete shall be carried out by an independent laboratory
    qa
    approved by the Engineer.
    as

    2 The evaluation of concrete in structure is needed when an existing structure is to be modified


    or redesigned; to assess structural adequacy when doubt arises about the compressive
    se

    strength in the structure due to defective workmanship, deterioration of concrete due to fire or
    other causes;when an assessment of the in-situ concrete strength is needed during
    er

    construction; to assess structural adequacy in the case of non-conformity of the compressive


    strength obtained from standard test specimens; assessment of conformity of the in-situ
    ov

    concrete compressive strength when specified in a specification or product standard.

    13.1.5 Non-Compliance of Work


    it o

    1 If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum
    et

    criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the
    m

    concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

    2 The parts or elements of the structure made from the defective batch or batches of concrete
    as represented by the works test cubes shall be identified by the Engineer and based on this
    information the Engineer shall instruct the Contractor on the required number and position of
    concrete cores.

    3 The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or
    ACI 318 whichever is applicable to the structural design.

    4 Based on this assessment the Engineer shall decide the acceptability of the concrete in the
    structural element and may either:

    (a) accept the concrete


    (b) instruct that certain remedial works are carried out
    (c) instruct that the element is replaced.
    QCS 2014 Section 05: Concrete Page 4
    Part 13: Inspection and Testing of Hardened Concrete

    13.1.6 General Fieldwork Requirements

    1 The Contractor shall make all arrangements to provide safe stable access to testing
    locations.

    2 When gaining access to testing locations and whilst testing the Contractor shall take care not
    to damage the structure or leave it in an untidy or unclean state.

    3 The Contractor shall take precautions to ensure that cooling water from concrete coring/other
    operations is discharged such as not to cause a mess or damage the interior or exterior parts
    of the structure.

    4 The Contractor shall be responsible for arranging the water supply required for testing.

    5 The Contractor shall arrange for a suitable power supplies. Where testing is being carried out

    l .
    on an occupied structure a power supply from the building services may not available and the

    .l.
    Contractor shall make arrangements for power supply and extension leads of adequate

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    length.

    6 The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field

    ta
    work. The supervisor shall have not less than five years experience of such work.
    qa
    7 Before starting the work, the Engineer with the Contractors supervisor will mark the positions
    where field testing is to be carried out. A unique referencing system to identify each sample
    as

    or testing location will be adopted, and this will either be referenced on sketch plans or
    drawings or by a detailed description used throughout the report to identify test locations.
    se

    8 If testing is being carried out on an occupied structure the Contractor shall co-ordinate with
    the owner or operator of the structure to arrange the detailed programme for the works and
    er

    gain access to the various parts of the structure.


    ov

    9 As soon as laboratory test results are available these shall be submitted by hand or faxed to
    the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing
    o

    agency, assigned by the contractor shall provide a technical report providing visual
    it

    information and analysing the tests conducted.


    et

    10 All core holes, dust sample holes and exploratory investigation areas shall be reinstated with
    m

    a proprietary non shrink cementitious repair mortar. The preparation of the hole or area
    before reinstatement shall be carried out as per the recommendation of the repair mortar
    supplier.

    11 Before filling any core holes, dust sample holes or exploratory investigation areas, the
    Contractor shall allow the Engineer time to inspect these areas and obtain written
    confirmation from the Engineer before filling.

    13.2 CONCRETE CORES

    13.2.1 General

    1 The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS
    EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the
    structural design.
    QCS 2014 Section 05: Concrete Page 5
    Part 13: Inspection and Testing of Hardened Concrete

    2 All of the supplementary information listed by the relevant standards shall be included in the
    test report with photographs of the cores.

    3 An assessment of in-situ compressive strength for a particular test region shall be based on
    at least 3 cores. Consideration shall be given to any structural implications resulting from
    taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation
    unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

    4 The preferred minimum core diameter is three times the nominal maximum size of the
    coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse
    aggregate

    5 The Engineer will advise the required number and locations of cores. If the results of the
    initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain
    locations.

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    .l.
    6 Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not

    rw
    cut through any reinforcing steel. The required diameter and depth of concrete cores shall be
    as stated in table 13.1

    Table 13.1
    ta
    qa
    1
    Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823)
    as

    Thickness of Minimum Depth to Be


    Types of Construction
    Section, m Sampled, m
    se

    Slabs, pavements, walls, linings, foundations, 0.3 or less entire depth


    structural elements accessible from one side 0.3 or greater 0.3
    er

    only
    2
    Suspended slabs , walls, conduits, 0.15 or less entire depth
    ov

    foundations, structural elements exposed to


    the atmosphere at two or more sides; 0.15 0.6 one half the thickness or
    0.15 whichever is greater
    o

    concrete products
    it

    Massive sections 0.6 or greater 0.6


    et
    m

    1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples
    that are required for all tests, in that case, the necessary additional quantity of concrete in
    pieces of appropriate minimum size should be taken at each sampling location.

    2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as
    not to lose the core by its falling from the barrel and to make it easier to patch the core hole.

    13.2.2 Drilling Cores

    1 Before beginning coring operations the Contractor shall use a proprietary cover meter to
    identify the position of steel reinforcing bars at the testing location.
    QCS 2014 Section 05: Concrete Page 6
    Part 13: Inspection and Testing of Hardened Concrete

    2 The Engineer may instruct that the core is taken through the concrete without hitting any
    reinforcement or the Engineer may instruct that the core is taken in a position where it is
    expected reinforcement will be cut in order to provide a sample of the reinforcement to check
    its condition. The locations of all drilling points shall be chosen so that the core contains no
    steel parallel to its length.

    3 Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared
    for test the core shall have a length at least equal to the diameter and not more than 1.2
    times its diameter.

    4 Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the
    aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm
    cores should be taken to reduce the variability due to drilling and increase the reliability of the
    testing, unless reinforcement is congested and the use of 100 mm cores will reduce the
    possibility that the core will contain steel or it is necessary to restrict the sampling to a length

    l .
    of less than 150 mm.

    .l.
    rw
    5 Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores
    may be used with the permission of the Engineer.

    6
    ta
    During drilling operations, a log of observations that may affect the interpretation of core
    qa
    samples shall be prepared.

    7 If instructed by the Engineer, immediately after the core has been cut and removed and the
    as

    structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein


    poured over the cut surface. A photograph shall be taken of the cut core with the
    se

    phenolphthalein solution applied to provide a record of the test.


    er

    8 If during the drilling of the core, the core collapses due to weak honeycombed or defective
    concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent
    ov

    location as advised by the Engineer. If when testing at the second location, the core again
    breaks due to honeycombed or defective concrete the freshly cut core shall be retained for
    reference and a note made of the condition.
    it o

    13.2.3 Testing for Strength


    et

    1 The compressive strength of field concrete cores shall be assessed in accordance with BS
    m

    EN 13791.

    2 The details of the concrete core in accordance with BS EN 13791 shall be recorded and two
    photographs on either side of the core taken.

    3 Where there is reinforcement in the core, the size and the type of bar shall be noted along
    with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a
    detailed description of any corrosion of the reinforcement.

    4 Before carrying out the compressive strength testing of the cores, the Contractor shall inform
    the Engineer to allow him to witness the testing if required.

    5 Crushed core samples shall be retained by the laboratory and only disposed of after written
    approval by the Engineer.
    QCS 2014 Section 05: Concrete Page 7
    Part 13: Inspection and Testing of Hardened Concrete

    13.2.4 Assessment of Strength

    1 The estimated in-situ strength of the concrete shall be calculated from the core result using
    BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

    13.3 REINFORCEMENT COVER MEASUREMENTS

    1 The measurement of cover to reinforcing steel and other metallic items in concrete shall be
    carried out in accordance with BS 1881 Part 204 using an electromagnetic device that
    estimates the position depth and size of the reinforcement.

    2 The locations for checking cover and the spacing between measurements shall be advised
    by the Engineer based on the objective of the investigation. The Contractor shall carry out
    calibrations of the electric magnetic device for a particular bar size to allow the bar diameter

    .
    to be measured.

    l
    .l.
    3 While testing, the orientation of steel bars shall be checked.

    rw
    4 The electromagnetic device shall incorporate scale or digital display range and shall be
    calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the

    ta
    indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever
    qa
    is the greater over the working range given by the manufacturer.

    5 The cover meter shall be used in accordance with the manufacturers instructions and checks
    as

    on the zero carried out as specified.


    se

    6 The search head shall be traversed systematically across the concrete, and, where
    reinforcement is located, rotated until the maximum disturbance with electromagnetic field is
    er

    indicated by the meter.


    ov

    7 The cover to the reinforcement shall be noted along with the axis of the reinforcement. The
    cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent
    marking pen.
    it o

    8 Care should be taken to avoid interference from other metallic sources or magnetic material.
    et

    9 The cover meter checks shall be carried out by an operator with five years experience.
    m

    10 The test report on cover shall include the following information:

    (a) date
    (b) time and place of test
    (c) description of the structure or component under investigation
    (d) location of test areas
    (e) make and type of cover meter used
    (f) date of last laboratory calibration of cover meter
    (g) details of site calibration of cover meter, indicated values of cover
    (h) estimated accuracy of quantitative measurements
    (i) configuration of steel reinforcement
    QCS 2014 Section 05: Concrete Page 8
    Part 13: Inspection and Testing of Hardened Concrete

    13.4 ULTRASONIC PULSE MEASUREMENTS

    13.4.1 General

    1 The ultrasonic velocity test equipment shall be capable of measuring the transit time of a
    pulse vibration through concrete. The length of the pulse part between the transducer
    equipment shall be measured, and the pulse velocity calculated.

    2 Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS
    EN 12504-4.

    3 Velocities shall be measured at a number of locations around a structure and a velocity


    contour of the structure established. A minimum of 40 velocities shall be measured for each
    structural element.

    l .
    13.4.2 Selection of Test Locations

    .l.
    rw
    1 Wherever possible direct transmission arrangements shall be used. The transducers shall be
    mounted on a specially formed moulded surface.

    2
    ta
    The minimum path length shall be 100 mm for concrete in which the nominal maximum size
    qa
    of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size
    of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than
    required to detect small regions of bad concrete.
    as

    3 Where concrete contains steel the pulse velocity shall be adjusted in accordance with the
    se

    requirement of BS EN 12504-4.
    er

    4 Locations that contain reinforcement directly along or close to the pulse paths shall be
    avoided.
    ov

    5 Where repositioning is not possible the semi-direct transmission measurement, where


    transducers are placed on adjacent faces of the concrete, may be used.
    it o

    13.4.3 Execution of Tests


    et

    1 Positions chosen for the test locations shall be clearly and accurately marked on the surface
    m

    of the concrete.

    2 The surface of the concrete shall be shall be cleaned and free from grit and dust. Path
    lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease)
    applied to each of the test points.

    3 Pulse transit times shall be measured by a skilled operator, with a minimum of five years
    experience in the use of the equipment.

    4 Pulse velocity measurement equipment shall be in accordance with the requirements of BS


    EN 12504-4.

    5 Test results shall be examined and any unusual readings repeated carefully for verification or
    amendment.
    QCS 2014 Section 05: Concrete Page 9
    Part 13: Inspection and Testing of Hardened Concrete

    13.4.4 Estimated In-Situ Cube Strength

    1 A correlation shall be established between the cube crushing strength of the particular mix
    used in the structure and the pulse velocity.

    2 Where it is not possible to obtain cubes with the same mix design as the original structure a
    combination of coring and ultrasonic pulse velocity testing may be carried out at the direction
    of the Engineer, where the cores are used to provide the correlation information required for
    the interpretation of the ultrasonic pulse velocity tests.

    13.5 RADIOGRAPHY OF CONCRETE

    1 Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects:
    The testing shall be carried out in accordance with the requirements of BS 1881-205 or

    .
    equivalent.

    l
    .l.
    13.6 SURFACE HARDNESS

    rw
    13.6.1 General

    1
    ta
    Testing of concrete surfaces for hardness using rebound hammers shall be carried out in
    qa
    accordance with BS EN 12504-2.

    2 The rebound hammer shall only be used for estimation of concrete strength where a specific
    as

    correlation is carried out of the concrete from the structure being tested; this shall be from
    works test cubes or cores taken from the structure.
    se

    3 The correlation between concrete strength and the rebound number shall be carried out in
    er

    accordance with BS EN 12504-2. The precision of the correlation curve between the mean
    rebound number and strength shall be stated and this shall be used when reporting any
    ov

    strength interpretations from surface hardness readings. The use of general manufacturers
    correlation or calibration curve for strength shall not be used.
    o

    4 It should be noted that the rebound hammer number only provides information on a surface
    it

    layer of approximately 30 mm in depth of the concrete and that this should be quoted in the
    et

    test report.
    m

    5 The rebound hammer maybe used to establish the uniformity of the finish products or similar
    elements in a structure at a constant age, temperature, maturity and moisture condition.

    13.6.2 Method of Test

    1 A minimum of 12 readings shall be taken to establish a single surface hardness at a


    particular location.

    2 The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not
    exceeding 300 mm by 300 mm.

    3 The mean of each set of readings shall be calculated including abnormally high and
    abnormally low results unless there is good reason to doubt the validity of a particular
    reading.

    4 The coefficient of variation and the standard deviation of the readings shall be reported.
    QCS 2014 Section 05: Concrete Page 10
    Part 13: Inspection and Testing of Hardened Concrete

    13.6.3 Equipment

    1 The rebound hammer shall be a proprietary type that has been used successfully and
    serviced for a minimum of five years.

    2 The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact
    with the surface.

    3 The manufacturers literature shall identify the impact energy and contact area of the plunger
    for the hammer.

    13.6.4 Reporting

    1 The test report shall affirm that the hardness was determined in accordance with BS EN
    12504-2 and shall provide the following information:

    l .
    .l.
    (a) date time and place of test

    rw
    (b) description of structure and location of test
    (c) details of concrete
    (d) type of cement
    ta
    qa
    (e) cement content
    (f) type of aggregate
    as

    (g) type of curing


    se

    (h) age of concrete


    (i) type of compaction of concrete
    er

    (j) forming of surface


    ov

    (k) moisture condition of the surface


    (l) carbonation state of surface
    o

    (m) any suspected movement of the concrete under test


    it
    et

    (n) direction of test


    m

    (o) any other factors that are considered significant in influencing the hardness readings.

    2 The details of the rebound hammer correlation with strength including the mean, range,
    standard deviation and coefficient and variation of each reading shall also be included.

    13.7 CHEMICAL CONTENT

    13.7.1 Sampling

    1 The Engineer shall instruct the depth increments over which the dust samples are to be
    taken, the types of chemical testing to be carried out and the quantity of sample required.

    2 The depth of sample shall not be less than the concrete cover to the reinforcement and at
    least 50 mm from the surface of concrete. In presence of reinforcement, the chemical
    content shall be tested at least at two levels before and after the depth of reinforcement from
    the surface of concrete.
    QCS 2014 Section 05: Concrete Page 11
    Part 13: Inspection and Testing of Hardened Concrete

    3 To provide uniform samples of cement matrix and aggregate, three separate holes shall be
    drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

    4 Care shall be taken to discard the material from any render or finish unless this is specifically
    required under the investigation.

    5 Care shall be taken to ensure that dust increments are accurately measured by marking the
    drill bit.

    6 The dust samples increments shall be carefully transferred to plastic bags and sealed to
    avoid contamination. Each sealed bag shall be uniquely identified by the sample identification
    and depth increment.

    13.7.2 Laboratory Testing

    l .
    1 Residual split samples of dust from the field investigation shall be retained until the Engineer

    .l.
    has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried

    rw
    out on certain samples.

    2 Chloride testing of concrete dust samples shall be by an acid soluble method in accordance

    ta
    with BS 1881 Part 124. The results shall be reported to two decimal places.
    qa
    3 Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124,
    using an acid soluble method.
    as

    END OF PART
    se
    er
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    it o
    et
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    QCS 2014 Section 05: Concrete Page 1
    Part 14: Protective Treatments for Concrete

    14 PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2


    14.1 GENERAL ............................................................................................................... 2
    14.1.1 Scope 2
    14.1.2 References 2
    14.1.3 Submittals 2
    14.1.4 Quality Assurance 3
    14.1.5 Preinstallation and Co-ordination 4
    14.1.6 Delivery, Storage and Handling 4
    14.1.7 Protection 4
    14.1.8 General Requirements for all Treatments 5
    14.1.9 Final Inspection 5
    14.2 EPOXY COATING ................................................................................................... 5

    .
    14.2.1 General 5

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    .l.
    14.2.2 Surface Preparation 5
    14.2.3 Materials 6

    rw
    14.2.4 Application 6
    14.3 WATERPROOF MEMBRANE ................................................................................. 6
    14.3.1 General ta 6
    qa
    14.3.2 Materials 7
    14.3.3 Waterproof Membrane 7
    14.3.4 Application 7
    as

    14.4 PENETRATIVE PRIMER ......................................................................................... 8


    se

    14.4.1 General 8
    14.4.2 Material 8
    er

    14.4.3 Surface Preparation 8


    14.4.4 Application 8
    ov

    14.5 PROTECTIVE COATING ........................................................................................ 9


    14.5.1 General 9
    o

    14.5.2 Surface Preparation 9


    it
    et

    14.5.3 Material 10
    14.5.4 Application 10
    m

    14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11


    14.6.1 General 11
    14.6.2 Shop Drawings and Submittals 11
    14.6.3 Liner Material Requirements 11
    14.6.4 Plastic Sheet Liner Strip Properties 12
    14.6.5 Basic Sheet Dimensions 12
    14.6.6 Liner Details 12
    14.6.7 Installation 13
    14.6.8 Testing Requirements 13
    14.6.9 Special Requirements 14
    14.6.10 Joints in Lining for In-Situ Concrete Structures 15
    14.6.11 Testing and repairing damaged surfaces 15
    QCS 2014 Section 05: Concrete Page 2
    Part 14: Protective Treatments for Concrete

    14 PROTECTIVE TREATMENTS FOR CONCRETE

    14.1 GENERAL

    14.1.1 Scope

    1 This Part covers the materials and application requirements for coatings for concrete
    surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective
    coatings, and coatings and treatments for specialist applications where there is a harsh
    environment.

    2 Related Section and Parts are as follows:


    This Section

    .
    Part 1, ............. General

    l
    .l.
    14.1.2 References

    rw
    1 The following standards are referred to in this Part:

    ta
    ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers
    Tension
    qa
    ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents
    ASTM D570 ................Test Method for Water Absorption of Plastics
    as

    ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)


    ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers
    se

    by Impact
    ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting
    er

    ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for
    ov

    Electrical and Electronic Applications


    ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting
    o

    ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion
    it

    Testers
    et

    ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials


    ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth
    m

    Under Concrete Slabs, on Walls, or as Ground Cover


    BS 1881......................Testing Concrete
    BS EN 12350..............Testing fresh concrete

    CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments.


    ISO 9000 ....................Quality management and quality assurance standards
    ISO 9001 ....................Quality systems - Model for quality assurance in design, development,
    production, installation and servicing

    14.1.3 Submittals

    1 The Contractor shall submit manufacturers' specifications, installation instructions and other
    data to show compliance with the requirements of this part of the specification and the
    Contract Documents.
    QCS 2014 Section 05: Concrete Page 3
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall submit samples of all materials to be used in the works before delivery
    of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples
    of liquid components shall be a minimum of one litre.

    3 The Contractor shall submit comprehensive test results for the protective coating system as
    per the tests in the specification which shall clearly indicate whether the values are mean
    values measured in current production or minimum values which the property does not fall
    below.

    4 The Contractor shall clearly state the chemical composition of the material and the process
    by which protection is given to the concrete.

    5 In addition to the test methods identified in this clause of this specification, the Engineer may
    require the Contractor to carry out further tests to different standards.

    l .
    6 If the Contractor wishes to propose a material which has been tested to alternative

    .l.
    standards, the Contractor shall submit correlation tests showing the comparable values of the

    rw
    two test methods. These test results shall be comprehensive giving full details of the sample
    conditioning, preparation, method of test, criteria for assessment etc.

    7
    ta
    The Contractor shall submit comprehensive information of previous applications of the
    material in similar conditions and environments. This information shall include: project name,
    qa
    type/grade of material used, quantity of material used, name of client, name of consultant,
    name of Contractor. If requested by the Engineer, the Contractor shall supply the contact
    as

    details of the client, consultant or Contractor where the material was previously installed.
    se

    8 The Contractor shall submit a guaranty for the protective coating system and the
    workmanship. The guaranty shall be worded to reflect the required performance of the
    er

    material and shall be approved by the Engineer. The guaranty shall be worded to include the
    phrase the Contractor shall, at the convenience of the Employer, effect all repairs and
    ov

    replacements necessary to remedy defects all to the complete satisfaction of the Engineer.
    Unless stated otherwise in the contract specific documentation, the performance guaranty
    shall be for a period of ten years except for the penetrative primer which shall be for a period
    o

    of five years.
    it
    et

    9 The use of alternatives may be considered by the Engineer. If the Contractor wishes to
    propose such systems, a technical submission shall be made which shall include a
    m

    comprehensive justification giving an explanation of why the proposed system is equivalent


    or superior to the one designated.

    14.1.4 Quality Assurance

    1 The protective coating system shall be supplied by a manufacturer who is certified to the
    ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of
    the ISO 9000 series certificate that clearly states the scope of the certification.

    2 The protective coating system shall be supplied by a manufacturer who provides technical
    assistance on the suitability for the application and installation for the material. For the initial
    use of the material on Site, the Contractor shall arrange for the technical representative of
    the manufacturer to be present to demonstrate the correct use of the material.
    QCS 2014 Section 05: Concrete Page 4
    Part 14: Protective Treatments for Concrete

    3 The protective coating system shall be applied by a contractor or subcontractor who is


    certified to the ISO 9000 series of quality standards. The Contractor shall submit to the
    Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification.
    the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the
    applicator works to a quality system that is approved by the Engineer.

    4 The works shall be executed by an approved specialist subcontractor having a minimum of 5


    years successful experience in the installation of the specified material. Only tradesmen
    experienced with the installation of the materials specified shall be used.

    14.1.5 Preinstallation and Co-ordination

    1 After approval of all materials and before installation, a prework conference with the Engineer
    shall be held at the Site. The meeting shall be attended by representatives of the Engineer,
    Contractor, subcontractor, and manufacturer.

    l .
    .l.
    2 The parties shall:

    rw
    (a) review drawings, specifications and approved materials
    (b) correct conflicts, if any, between approvals and specification requirements
    (c) ta
    examine Site conditions, including inspection of substrate, material labels and
    qa
    methods of storing materials
    (d) review installation procedures and scheduling
    as

    (e) review protection methods for finished work from other trades.
    se

    3 Before applying the coating system to the permanent works the Contractor shall carry out a
    small trial of the coating system for the review and approval of the Engineer.
    er

    14.1.6 Delivery, Storage and Handling


    ov

    1 Materials shall be delivered in their original, tightly sealed containers or unopened packages,
    o

    all clearly labelled with the manufacturer's name, brand name, and number and batch
    number of the material where appropriate. Materials and equipment shall be stored as
    it

    directed in a neat and safe manner.


    et
    m

    2 Storage areas shall comply with the manufacturers requirements with regard to shade,
    ventilation and temperature limits and shall be located away from all sources of excess heat,
    sparks or open flame. Containers of liquid material shall not be left open at any time in the
    storage area.

    3 Materials not conforming to these requirements will be rejected by the Engineer and shall be
    removed from the Site and replaced with approved materials.

    4 The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and
    at such times as to permit proper co-ordination of the various parts.

    14.1.7 Protection

    1 The Contractor shall protect the protection system installation from damage during the
    construction period so that it will be without any indication of abuse, defects or damage at the
    time of completion.
    QCS 2014 Section 05: Concrete Page 5
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall protect the building/structure from damage resulting from spillage,
    dripping and dropping of materials.

    3 The Contractor shall prevent any materials from running into and clogging drains.

    4 Materials and plant shall not be stored on any newly constructed floor without the permission
    of the Engineer.

    5 Impervious membranes shall be laid as protection to all concrete surfaces in contact with the
    soil and shall consist of tanking or similar accepted material, based on soil investigation
    report.

    6 All foundations shall be provided with protection such as epoxy coatings or similar other
    accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

    l .
    14.1.8 General Requirements for all Treatments

    .l.
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    1 Protective treatments shall be applied where designated in the contract specific
    documentation.

    2
    ta
    All protective coating systems to be used shall be applied strictly in accordance with the
    manufacturers recommendations.
    qa
    3 The Contractor shall take all necessary precautions against fire and other hazards during
    as

    delivery, storage and installation of flammable materials specified herein and comply any
    regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect
    of the storage and use of hazardous materials required under this section.
    se

    4 The Engineer shall specify the required final colour of the coating and the Contractor shall
    er

    submit samples showing the colour before ordering the materials.


    ov

    14.1.9 Final Inspection


    o

    1 Upon completion of the installation, an inspection shall be made by a representative of the


    it

    material manufacturer in order to ascertain that the system has been properly installed.
    et

    14.2 EPOXY COATING


    m

    14.2.1 General

    1 The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in
    two coats to a dry film thickness of 200 m minimum.

    14.2.2 Surface Preparation

    1 The surface of the concrete shall be free from oil, grease, loose particles, decayed matter,
    moss or algae growth and general curing compounds. All surface contamination and surface
    laitance shall be removed by high pressure water jetting or sweep blasting.

    2 Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic
    epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with
    the product manufacturers recommendations.
    QCS 2014 Section 05: Concrete Page 6
    Part 14: Protective Treatments for Concrete

    3 Where surface cracking is apparent these cracks shall be chased, by an approved


    mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using
    a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased
    section and providing a flush finish with the concrete surface. A minimum period of 24 h shall
    be allowed before applying any subsequent protective coating systems.

    14.2.3 Materials

    1 External above ground coating materials shall provide protection against chlorides and
    carbonation, and be UV and abrasion resistant.

    2 The above ground coating shall be applied over the below ground coating and shall continue
    for a minimum of 150 mm above the ground level.

    3 The epoxy coating shall be UV stable.

    l .
    .l.
    4 The finished coating shall be pinhole free and have a total minimum dry film thickness of

    rw
    200 m.

    5 The materials used in the coating system shall comply with the following requirements:

    ta
    qa
    Solids content > 85 %
    Service temperature -20 C to 70 C
    Tensile strength (DIN 53504) 4 MPa
    as

    Resistance against crack (DIN 53515) 6 MPa


    Adhesion to concrete (ASTM D-4541) greater than 3.5 MPa
    Compressive strength (ASTM D-695) 90 MPa (neat resin)
    se

    Tensile elongation (ASTM D-638) 6-8 % (neat resin)


    Water absorption (MIL D-24613) Nil
    er

    Abrasion resistance (ASTM C-501) 50 mg


    Compressive strength (ASTM C-579) 97 MPa @ 7 days
    ov

    -6
    Thermal coefficient of expansion (ASTM C-531) 46.8 x 10 mm/mm/degree C
    o

    14.2.4 Application
    it
    et

    1 Where required by the Engineer, trial areas not exposed in the finished work shall first be
    treated using the selected materials.
    m

    2 The exposed concrete surfaces as defined in the documents or as agreed with the Engineer
    shall be treated with the material.

    3 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the
    Engineer.

    4 In all operations of storage, mixing and application, the Contractor is to comply with the
    health and safety recommendations of the manufacturer and governing authorities.

    14.3 WATERPROOF MEMBRANE

    14.3.1 General

    1 This Subpart covers the use of waterproof membrane for general protection to buried
    concrete.
    QCS 2014 Section 05: Concrete Page 7
    Part 14: Protective Treatments for Concrete

    2 Where indicated on the Drawings or directed by the Engineer, concrete in contact with the
    ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

    3 The laying, lapping and sealing of the membrane shall be in accordance with the
    manufacturers instructions.

    14.3.2 Materials

    1 The material shall be an externally applied waterproof membrane shall be an impervious,


    cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated
    polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with
    silicone coated release paper.

    2 Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

    l .
    3 Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured

    .l.
    from selected aggregates, bound in modified bitumen encased between two layers of

    rw
    strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick
    and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm
    wide.

    14.3.3 Waterproof Membrane ta


    qa
    1 The material shall be suitable for use in the Gulf region the compound shall be specially
    as

    formulated for hot climates and shall have proven experience in the Middle East.
    se

    2 The waterproofing material shall conform to the standards detailed in Table 14.1
    er

    Table 14.1
    Waterproof Membrane Property Requirements
    ov

    Property Standard Value


    o

    Longituduial 210 %
    Elongation Film ASTM D638
    it

    Transverse 160 %
    et

    Longitudinal 340 MPa


    Tear resistance ASTM D1004
    Transverse 310 MPa
    m

    Adhesion to primed concrete ASTM D1000 1.8 MPa

    Elongation compound ASTM D1000 1.8 MPa

    Puncture resistance ASTM E154 220 N over 65 mm


    After 24 h. 0.14 %
    Water resistance ASTM D570
    After 35 d 0.95 %
    Environmental resistance ASTM D543
    2
    Moisture vapour transmission rate ASTM E96 0.3g/M 24 h
    Minimum thickness 1.0 mm.

    14.3.4 Application

    1 Waterproofing membranes placed on vertical concrete faces shall be protected by preformed


    asphalt board.
    QCS 2014 Section 05: Concrete Page 8
    Part 14: Protective Treatments for Concrete

    2 Boards shall be bonded onto position with high quality solvent borne contact adhesive based
    on polychloroprene rubber.

    3 The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains,
    equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

    4 Areas where waterproofing is applied shall be protected from all traffic and where necessary
    backfilling. All damage to finished portions of the waterproofing membrane shall be either
    repaired or replaced, or both, in a manner acceptable to the Engineer.

    14.4 PENETRATIVE PRIMER

    14.4.1 General

    1 The system shall be a penetrating hydrophobic treatment that protects concrete from both

    l .
    water and chloride intrusion, while permitting water vapour transmission.

    .l.
    rw
    2 The treatment shall significantly reduce the absorption of water and water borne salts but
    allow the transmission of water vapour from the substrate.

    3
    ta
    The treatment shall not produce any discoloration of the substrate and shall have excellent
    qa
    resistance to weathering.

    14.4.2 Material
    as

    1 The material shall be a low viscosity silane-siloxane system which penetrates deeply into a
    se

    porous substrate and reacts to produce a bonded hydrophobic lining to the pores.
    er

    2 The material shall be resistant to petrol, oil, and atmospheric contaminants such as car
    exhaust fumes and industrial exhausts.
    ov

    14.4.3 Surface Preparation


    o

    1 The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae
    it

    growth and curing compounds.


    et

    2 If the concrete surface is newly cast and has a very smooth finish, the surface shall be
    m

    roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer
    shall decide if this means of preparation is required.

    3 Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in
    accordance with the manufacturers recommendations.

    4 Concrete finishing required shall be completed before the application of the treatment.

    5 Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturers
    recommendations.

    14.4.4 Application

    1 Unless directed otherwise by the Engineer the treatment shall be applied a minimum period
    of 24 h after the wet curing period, and shall be surface dry.
    QCS 2014 Section 05: Concrete Page 9
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall carry out tests to verify the depth of penetration of the material. These
    tests shall be carried out on specimens of the actual mix design and shall use coloured dyes
    to trace the penetration of the material.

    3 Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for
    reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats'
    of the treatment shall be applied before the main treatment.

    4 The application of the material on surfaces shall be by a low pressure spray direct from the
    can. Under no circumstances should thinning of the material be carried out.

    5 The rate of application shall ensure that the surface is completely saturated. The
    impregnated coating shall be applied to two or more flood coats each flood coat shall be a
    2
    minimum of 0.4 l/m .

    l .
    6 The material shall be applied strictly in accordance with the manufacturers instructions and

    .l.
    as follows:

    rw
    (a) the material shall be applied by a fine nozzle spray
    (b) application will not be permitted when the ambient air temperature is above 35 C or
    in windy conditions
    ta
    qa
    (c) the surface shall be cleaned by a stiff brush or compressed air to remove all loose
    deposits
    as

    (d) concrete to be treated shall be surface dry for a minimum period of 24 h before
    impregnation
    se

    (e) membranes, joint sealers and cast in concrete ancillaries shall be masked off before
    treatment
    er

    (f) application shall be made by saturation flooding


    ov

    (g) the interval between application shall be at least 6 h


    (h) treated areas shall be protected from sea water and rain for 6 h after treatment.
    it o
    et

    14.5 PROTECTIVE COATING


    m

    14.5.1 General

    1 The coating system shall be used for the protection of new or existing reinforced concrete
    structures against carbonation or chloride induced corrosion.

    2 The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat
    system to minimise ingress of acidic gases, chlorides and water.

    14.5.2 Surface Preparation

    1 Before application, all surfaces must be dry and free from oil, grease, loose particles,
    decayed matter, moss or algae growth and general curing compounds.

    2 All such contamination and laitence must be removed by the use of grit blasting, high
    pressure water jetting or equivalent mechanical means.
    QCS 2014 Section 05: Concrete Page 10
    Part 14: Protective Treatments for Concrete

    3 Before proceeding to apply the protective coatings, all surfaces which are not to be coated
    but which may be affected by the application of the coating shall be fully masked and, in
    particular, flora and fauna shall be protected.

    4 Blow holes and areas of pitting shall be made good with a one part modified cementitious
    material and allowed to cure in accordance with the manufacturer's recommendations. In
    particular, the application shall be in accordance with the manufacturer's recommendations,
    with respect to the maximum application thickness.

    14.5.3 Material

    1 The materials are required to provide in-depth protection against carbonation and chloride
    penetration whilst permitting water vapour transmission from the concrete.

    2 The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a

    l .
    porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

    .l.
    rw
    3 The material employed for the coating shall comply with the following requirements:
    Wet film thickness 400 m
    Dry film thickness 200 m
    Carbon Dioxide diffusion resistance
    ta R Value at 325 microns > 161 metres.
    qa
    (Taywood Engineering Laboratories)
    Water vapour transmission
    2
    (Taywood Engineering Laboratories) Shall be more than 13 g/m .d
    Reduction in chloride ion penetration 94 % minimum at 28 d
    as

    (BS 1881 : Part 124)


    2
    Tear Resistance (ASTM D624) 7.3 kN/mm
    se

    Crack bridging (BRE Method) 5.1 mm


    Chloride Ion Diffusion
    er

    -10 2
    (Taywood Engineering Labororatories) 3.63 x 10 cm /sec.
    4 Where test methods are not specified, the procedure for establishing compliance with the
    ov

    above criteria shall be agreed with the Engineer.


    o

    5 The Contractor is required to adhere strictly to the manufacturer's recommendations


    it

    regarding the use, storage, application and safety rules in respect of the approved materials.
    et

    14.5.4 Application
    m

    1 Where required by the Engineer, trial areas not exposed in the finished work shall first be
    treated using the selected materials. These trial areas shall be noted on the Drawings and
    shall be carried out using the type of materials, mixing procedures and applications that will
    be used on the contract and shall be approved by the Engineer before the Contractor
    commences with the general work.

    2 The exposed concrete surfaces as defined in the documents or as agreed with the Engineer
    shall be conditioned by the application of a penetrating hydrophobic treatment. The primer
    shall be allowed to dry in accordance with the manufacturer's requirements.

    3 The Contractor shall then apply two coats of pigmented topcoat in accordance with the
    manufacturer's instructions. The finished coating shall be pinhole free and have a total
    minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the
    Engineer.
    QCS 2014 Section 05: Concrete Page 11
    Part 14: Protective Treatments for Concrete

    4 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the
    Engineer.

    5 In all operations of storage, mixing and application the Contractor shall comply with the health
    and safety recommendations of the manufacturer and governing authorities.

    14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

    14.6.1 General

    1 This Subpart covers the supply and installation of sheet liners in reinforced concrete
    structures.

    2 The liner must be continuous and free of pinholes both across the joints and in the liner itself.

    l .
    3 All work for and in connection with the installation of the lining in concrete pipe and structure,

    .l.
    and the field sealing and welding of joints, will be done in strict conformity with all applicable

    rw
    specifications, instructions, and recommendations of the lining manufacturer.

    14.6.2 Shop Drawings and Submittals

    ta
    qa
    1 The Contractor shall submit to the Engineer for approval the following:

    (a) liner schedule


    as

    (b) material certifications


    (c) test results
    se

    (d) material samples


    er

    (e) the manufacturer of the lining will submit an affidavit attesting to the successful use
    ov

    of its material as a lining for sewer pipes and structures for a minimum period of
    five years in service conditions recognised as corrosive or otherwise detrimental to
    concrete.
    it o

    14.6.3 Liner Material Requirements


    et

    1 The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and
    m

    other components necessary to make a material of permanent flexibility suitable for a liner in
    concrete pipes and structures in sewerage service. The weld strips and the joint strips shall
    be made from like material. For PVC and PE sheet liners, the actual resin used in
    manufacture must constitute not less than 99 % of the resin used in the formulation.

    2 Copolymer resins will not be permitted.

    3 All plastic sheets including locking extensions, all joints and welding strips shall be free of
    cracks, asperities and other defects that may affect the protective properties of the material.

    4 The properties of PVC and PE sheet are shown in Table 14.2


    QCS 2014 Section 05: Concrete Page 12
    Part 14: Protective Treatments for Concrete

    Table 14.2
    Properties of PVC and PE Sheet Liners

    Property Test Method Requirement


    PVC
    Elongation at break ASTM D638/882 300 %
    Tensile Strength ASTM D638/412 15 MPa
    Low Temp. Brittleness ASTM D746 0C
    PE
    Elongation at break ASTM D638/882 Exceeds 600 %
    Tensile Strength ASTM D638/412 10-20 MPa
    Low Temp. Brittleness ASTM D746 -75 C

    14.6.4 Plastic Sheet Liner Strip Properties

    l .
    1 Except at shop welds, all plastic sheet liners and strips shall have the properties shown in

    .l.
    Table 14.3 when tested at 25 C.

    rw
    Table 14.3

    Property ta
    Properties of Plastic Sheet Liner Strips

    Requirement
    qa
    Tensile strength 15 MPa
    Elongation at break 200 %
    as

    1 s 50 - 60 5 (with respect to 10 s
    Shore Durometer
    35 - 50 5)
    se

    Weight change 1.5 %


    er
    ov

    14.6.5 Basic Sheet Dimensions

    1 The minimum thickness of the material shall be as shown in Table 14.4


    it o

    Table 14.4
    et

    Plastic Sheet Liner Minimum Dimensions


    m

    Material Thickness Structures


    Sheet with locking extensions 4.0 mm
    Sheet, plain 2.3 mm
    Joint strip 1.9 mm
    Weld strip 2.4 mm

    14.6.6 Liner Details

    1 Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be
    integrally extruded with the sheet.

    2 Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

    3 Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using
    an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall
    be repaired and retested.
    QCS 2014 Section 05: Concrete Page 13
    Part 14: Protective Treatments for Concrete

    14.6.7 Installation

    1 Installation of the lining, including preheating of sheets in cold weather and the welding of all
    joints, shall be performed in accordance with the recommendations of the manufacturer.

    2 The lining to be held snugly in place against inner forms by means of steel banding straps or
    other means recommended by the manufacturer.

    3 Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a
    careful manner to protect the lining and produce a dense, homogenous concrete, securely
    anchoring the locking extensions into the concrete.

    4 In removing forms care shall be taken to protect the lining from damage. In particular:

    (a) sharp instruments not to be used to pry forms from lined surfaces.

    l .
    (b) when forms are removed, any nails that remain in the lining to be pulled, without

    .l.
    tearing the lining, and the resulting holes clearly marked.

    rw
    (c) form tie holes to be marked before ties are broken off and all areas of serious
    abrasion or damage shall be marked.

    5
    ta
    All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be
    qa
    patched as follows:

    (a) patches made entirely with welding strip to be fused to the liner over the entire patch
    as

    area
    (b) larger patches may consist of smooth liner sheet applied over the damaged area with
    se

    adhesive
    er

    (c) all edges must be covered with welding strip fused to the patch and the sound lining
    adjoining the damaged area.
    ov

    6 Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.
    o

    7 The Contractor shall take all necessary measures to prevent damage to the installed lining
    it

    from equipment and materials used in or taken through the work.


    et

    14.6.8 Testing Requirements


    m

    1 Samples taken from sheets, joints or weld strips shall be tested to determine material
    properties. Determination of tensile strength and elongation shall be in accordance with
    ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with
    ASTM D 2240 using a Type D Durometer, except that a single thickness of material and
    indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of
    specimens shall be the thickness of the sheet or strip.

    2 The measurement of initial physical properties for tensile strength, weight, elongation and
    indentation hardness shall be determined before chemical resistance tests.

    3 Chemical resistance tests shall be carried out to determine the physical properties of the
    specimens after exposure to chemical solutions. Test specimens shall be conditioned to
    constant weight at 43 C before and after submersion in the solutions detailed in Table 14.5
    for a period of 112 d at 25 3 C.
    QCS 2014 Section 05: Concrete Page 14
    Part 14: Protective Treatments for Concrete

    4 Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals,


    specimens shall be removed from each chemical solution and tested. If any specimen fails to
    meet the 112 day exposure, the material will be subject to rejection.

    5 Pull test for locking extensions: Liner locking extensions embedded in concrete shall
    withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a
    period of 1 min, without rupture of the locking extensions or withdrawal from embedment.
    This test shall be made at a temperature between 21 C to 27 C inclusive.

    6 Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together,
    shall be a least equal to the minimum requirements of the liner for thickness, corrosion
    resistance and impermeability. Welds shall show no cracks or separations and shall be
    tested for tensile strength. Tensile strength measured across the welded joint in accordance
    with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25 3 C

    .
    and the measured minimum width and thickness of the reduced section shall be used.

    l
    .l.
    7 Spark test: All liner shall be shop tested for holes with a spark tester set to provide from

    rw
    15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before
    shipment from the manufacturers plant.

    8
    ta
    The Contractor shall provide the Engineer with certified copies of test reports before the
    qa
    shipment of the product to the Site.
    Table 14.5
    Chemical Resistance Tests
    as

    Chemical Solutions Concentration


    se

    Sulphuric Acid 20 %
    Sodium Hydroxide 5%
    er

    Ammonium Hydroxide 5%
    ov

    Nitric Acid 1%
    Ferric Chloride 1%
    o

    Soap 0.1 %
    it

    Detergent (Linear alkyl benzyl sulphonate or LAS) 0.1 %


    et

    Bacteriological BOD not less than 700 mg/l


    m

    Phosphoric Acid 50 %

    14.6.9 Special Requirements

    1 Liner sheets to be closely fitted and properly secured to the inner forms.

    (a) sheets that are to be cut to fit curved and warped surfaces shall use a minimum
    number of separate pieces
    (b) a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt
    joints to prevent wet concrete from flowing around the edges.

    2 Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the
    surfaces of contact between the concrete structure and items not of concrete and

    (a) the same procedure will be followed at joints where the type of protective lining is
    changed or the new work is built to join existing unlined concrete
    QCS 2014 Section 05: Concrete Page 15
    Part 14: Protective Treatments for Concrete

    (b) at each return, the returned liner will be sealed to the item in contact with the plastic
    lined concrete with an adhesive system
    (c) if the liner cannot be sealed with this adhesive because of the joint at the return being
    too wide or rough or because of safety regulations, the joint space shall be densely
    caulked with lead wool or other approved caulking material to a depth of 50 mm and
    finish with a minimum of 25 mm of an approved corrosion resistant material.

    14.6.10 Joints in Lining for In-Situ Concrete Structures

    1 Field joints and Lining at joints shall be free of all mortar and other foreign material and shall
    be clean and dry before joints are made.

    2 All welding is to be in strict conformance with the specifications of the lining manufacturer.

    .
    14.6.11 Testing and repairing damaged surfaces

    l
    .l.
    1 All surfaces covered with lining, including welds, will be tested with an approved electrical

    rw
    holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

    (a) all welds shall be physically tested by a non-destructive probing method


    (b) ta
    all patches over holes, or repairs to the liner wherever damage has occurred.
    qa
    2 Each transverse welding strip which extends to a lower edge of the liner will be tested by an
    approved testing agency at the cost of the Contractor.
    as

    (a) the welding strips will extend 50 mm below the liner to provide a tab.
    se

    (b) a 5 kg pull will be applied to each tab. The force will be applied normal to the face of
    the structure by means of a spring balance
    er

    (c) liner adjoining the welding strip will be held against the concrete during application of
    ov

    the force
    (d) the 5 kg pull will be maintained if a weld failure develops until no further separation
    o

    occurs.
    it

    (e) defective welds will be retested after repairs have been made
    et

    (f) tabs shall be trimmed away neatly by the installer of the liner after the welding strip has
    m

    passed inspection.
    (g) inspection will be made within two days after joints has been completed in order to
    prevent tearing the projecting weld strip and consequent damage to the liner from
    equipment and materials used in or taken through the work.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 15: Hot Weather Concreting

    15 HOT WEATHER CONCRETING ............................................................................. 2


    15.1 GENERAL ............................................................................................................... 2
    15.1.1 Scope 2
    15.1.2 References 2
    15.1.3 Definition of Hot Weather 2
    15.1.4 System Description 3
    15.1.5 Submittals 3
    15.2 PLACING TEMPERATURE ..................................................................................... 3
    15.3 PLANNING CONCRETING ..................................................................................... 4
    15.4 MIX DESIGN ........................................................................................................... 4
    15.5 TEMPERATURE CONTROL ................................................................................... 4
    15.5.1 General 4

    l .
    15.5.2 Aggregates 4

    .l.
    15.5.3 Water 5

    rw
    15.5.4 Cement 5
    15.5.5 Addition of Ice 5
    15.5.6 Liquid Nitrogen
    ta 6
    qa
    15.6 BATCHING AND MIXING ........................................................................................ 6
    15.7 TRANSPORTATION ............................................................................................... 6
    15.8 PLACING AND FINISHING ..................................................................................... 6
    as

    15.9 CURING AND PROTECTION.................................................................................. 7


    se

    15.10 INSPECTION AND TESTING .................................................................................. 7


    er
    ov
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 15: Hot Weather Concreting

    15 HOT WEATHER CONCRETING

    15.1 GENERAL

    15.1.1 Scope

    1 This Part covers the precautions to be taken for hot weather concreting for all structural
    concrete except blinding concrete, where a minimum compressive strength is specified.

    2 Related Sections and Parts are as follows:

    This Section
    Part 6, .............. Property Requirements
    Part 7, .............. Concrete Plants

    l .
    Part 8 .............. Transportation and Placing of Concrete

    .l.
    Part 10 ............. Curing

    rw
    15.1.2 References
    ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

    ta
    ASTM C1064 ..............Measuring the Temperature of Concrete
    qa
    BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for
    as

    buildings
    BS EN 480..................Admixtures for concrete, mortar and grout. Test methods
    se

    BS EN 934..................Admixtures for concrete, mortar and grout


    er

    15.1.3 Definition of Hot Weather


    ov

    1 The requirements of the following clauses of the specification are applicable during the hot
    weather period in Qatar.
    o

    2 The hot weather period shall be defined as starting when the maximum ambient air shade
    it

    temperature on the Site exceeds 35 C for three consecutive days. The end of the hot
    et

    weather period shall be defined as the period when the maximum air shade temperature is
    below 35 C on three consecutive days.
    m

    3 The Contractor shall establish a thermometer on Site that records the ambient air shade
    temperature. The thermometer shall be established at a position to provide representative air
    temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange
    for the calibration of the Site thermometer.

    4 Hot Weather shall mean any combination of the following conditions that tends to impair the
    quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and
    rate of cement hydration, or otherwise causing detrimental results such as:

    (a) High ambient temperature (when the shade temperature is above 40 deg C on a rising
    thermometer, 43 deg C on a falling thermometer),
    (b) High concrete temperature,
    (c) Low relative humidity,
    (d) High wind speed
    QCS 2014 Section 05: Concrete Page 3
    Part 15: Hot Weather Concreting
    2
    (e) the rate of evaporation exceeds 0.75 kg/m /h

    15.1.4 System Description

    1 The Contractor shall undertake hot weather concreting procedures that are effective in
    controlling the following potential problems associated with concreting in hot weather:

    (a) increased water demand of the mix


    (b) increased rate of slump loss
    (c) increased rate of setting
    (d) increased tendency for plastic shrinkage cracking
    (e) decreased long-term strength
    (f) increase tendency for drying shrinkage and cracking

    l .
    .l.
    (g) increased tendency for differential thermal effects with consequent cracking

    rw
    (h) decreased durability from cracking where there is increased permeability.

    15.1.5 Submittals

    1 ta
    The Contractor shall prepare weekly in advance his proposed concreting programme
    qa
    showing the quantities to be placed and the anticipated placing hours.

    2 At least one month before the start of the hot weather period the Contractor shall submit his
    as

    specific proposals for the control of the concrete temperature for the constituent materials;
    cement, water aggregates.
    se

    3 Where required the Contractor shall submit to the Engineer his proposals for the use of liquid
    er

    nitrogen for cooling which shall include details of previous project application and the
    intended methods to be used and quantities of liquid nitrogen.
    ov

    15.2 PLACING TEMPERATURE


    it o

    1 This Subpart of the specification applies at all times of the year and at all times of the day.
    et

    2 Maximum fresh concrete temperature (at placement) shall not exceed 32C unless
    m

    construction testing to verify a proposed concrete mixture will function satisfactorily at a


    concrete temperature greater than 32C. No concrete shall be placed if the concrete
    temperature is above 35C

    3 Concrete shall not be placed if the shade temperature exceeds 40C.

    4 The temperature of each truck of concrete shall be measured using either a glass, dial type
    or electronic thermometer, just before the placing of the concrete and the temperature
    recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire
    load of concrete in the truck or conveyer.

    5 The Contractor shall allow for the increase in concrete temperature in the period from
    dispatch from the plant while in transportation or whilst awaiting placement on Site and take
    adequate measures to ensure the maximum temperature is not exceeded.
    QCS 2014 Section 05: Concrete Page 4
    Part 15: Hot Weather Concreting

    15.3 PLANNING CONCRETING

    1 During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall
    plan concreting operations such that no concreting takes place between the hours of
    10:00 hours and 17:00 hours.

    2 The Contractor shall arrange concrete pours such that the programme of works can be
    achieved without concreting during the period from 10:00 hours to 17:00 hours.

    3 The Contractor shall nominate one member of his staff to be the co-ordinator for the supply
    of concrete. The co-ordinators responsibilities shall include ensuring the batched rate
    matches that of delivery and placement and the preparations needed before commencing a
    concrete pour.

    .
    15.4 MIX DESIGN

    l
    .l.
    1 In the hot weather period, the Contractor shall review all concrete mix designs to ensure that

    rw
    the design slump or workability specified is achieved without increase in the mix water
    content. The Contractor shall make modifications to the mix design to allow for increased
    slump loss during transportation in hot weather.
    ta
    qa
    2 This shall be achieved by adjusting the proportion of admixture, plasticiser or super
    plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix
    design with nominal values for cold weather and hot weather use.
    as

    3 Under no circumstances will the addition of extra water that increases the water cement ratio
    se

    be permitted during hotter weather.


    er

    4 All concrete materials and proportions used in periods of hot weather shall be those that have
    a satisfactory record of use in such conditions.
    ov

    15.5 TEMPERATURE CONTROL


    it o

    15.5.1 General
    et

    1 The Contractors specific proposals for the control of the concrete temperature shall include
    m

    extent and type of shading of aggregates, method of chilling mix water and procedures for
    batching and mixing, transportation, placing and finishing, curing and protection.

    2 These shall include calculations in accordance with ACI 305R, clause 3.1 estimating
    concrete temperature. The Contractor shall calculate the temperature of freshly produced
    concrete based on the input temperatures of the constituent materials and the weights from
    particular mix designs. The calculations shall make allowance for the rise in temperature
    between mixing and placing due to the transportation and waiting period. The calculations
    shall successfully demonstrate that the temperature can be maintained below 32 C at the
    point of placing.

    15.5.2 Aggregates

    1 All practical means shall be employed to keep the aggregates as cool as possible.
    QCS 2014 Section 05: Concrete Page 5
    Part 15: Hot Weather Concreting

    2 Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond
    the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is
    not incident on the aggregates. Shades shall be constructed to allow access for mechanical
    shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit
    the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool
    the aggregate.

    3 Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall


    not be permitted.

    15.5.3 Water

    1 Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

    2 The water shall be chilled by the use of proprietary chillers or the addition of ice to the water

    l .
    tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited

    .l.
    directly into the mixer.

    rw
    3 Water shall not be chilled below a temperature of 5 C.

    4
    ta
    Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and
    painted white.
    qa
    5 The mechanical refrigeration equipment and insulated water storage shall be adequate for
    as

    the anticipated hourly and daily production rates of concrete during the hot weather period.
    se

    6 Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank,
    such procedures shall be to the approval of the Engineer.
    er

    7 Ice shall be completely melted in mixing water prior to adding water to the mixer.
    ov

    15.5.4 Cement
    o

    1 The use of freshly ground cement at very high temperatures is not permitted.
    it
    et

    2 The cement shall be kept below the temperature which there is a tendency of false set.
    m

    3 Under no conditions shall the temperature of the cement exceed 75 C when it enters the
    mixture.

    4 The Contractor shall make arrangements for storage on Site to allow cooling of freshly
    ground and delivered cement.

    15.5.5 Addition of Ice

    1 Crushed shaved or chipped ice can be used as part of the mixing water for reducing the
    concrete temperature.

    2 The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted
    before the completion of mixing of the concrete in the pan.

    3 To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of


    the batch water requirement.
    QCS 2014 Section 05: Concrete Page 6
    Part 15: Hot Weather Concreting

    4 Crushed ice shall be stored at a temperature that will prevent lumps from forming by
    refreezing of particles.

    5 The batching plant shall incorporate a mechanical system for correctly proportioning and
    weighing the ice to be added to the mixture.

    6 The quantity of ice shall be deducted from the total batch water.

    7 The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated
    storage on the Site at the plant to meet the anticipated daily and hourly production rates of
    concrete during the hot weather period.

    15.5.6 Liquid Nitrogen

    1 Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

    l .
    .l.
    2 Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not

    rw
    frozen.

    3 The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and

    ta
    injection facility for the batching plant or one or more injection stations for truck mixers.
    qa
    4 The system may be set up at the Site for injection just before placing.

    5 Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.
    as

    15.6 BATCHING AND MIXING


    se

    1 The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.
    er
    ov

    2 Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with
    water and the drum flushed out with cold water before batching. Care shall be taken to
    ensure all water is removed from the drum before batching.
    it o

    3 The temperature of the concrete shall be checked after discharge from the mixer and written
    et

    on the delivery ticket. Temperature check shall be carried out at the plant on the concrete
    3
    floor for every 50 m produced or every hour which ever is the minimum.
    m

    4 A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN


    480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature
    conditions.

    15.7 TRANSPORTATION

    1 The transportation, placing, compaction and finishing of concrete shall be at the fastest
    possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of
    placement and compaction.

    15.8 PLACING AND FINISHING

    1 If the temperature of the first truck of concrete of a particular pour is above the specification
    maximum temperature limit then placing shall not commence.
    QCS 2014 Section 05: Concrete Page 7
    Part 15: Hot Weather Concreting

    2 If a pour is in progress and the temperature of a particular truck exceeds the maximum
    permitted temperature the placing may be allowed to continue at the discretion of the
    Engineer in order to avoid the possible development of a cold joint.

    3 However, no further concreting pours shall take place until the Contractor has submitted
    revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the
    maximum temperature will not be exceeded in the future. Before beginning new pours the
    temperature of the concrete constituent materials shall be monitored to verify that they meet
    the assumptions of the calculations.

    15.9 CURING AND PROTECTION

    1 Curing and protection shall conform to the requirements of Part 10 of this Section.

    2 Evaporation shall be minimised, particularly during the first few hours subsequent to placing

    l .
    concrete, by suitable means such as applying moisture by fog spraying or any other means

    .l.
    acceptable to the Engineer.

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    15.10 INSPECTION AND TESTING

    1
    ta
    All thermometers used for the measurement of concrete temperature shall be calibrated
    qa
    weekly against a glass mercury thermometer. Calibration shall be carried out over the
    temperature range of 10 C to 100 C using a water bath with ice or heating.
    as

    2 The method used to determine acceptance of temperature controlled concrete should be in


    accordance with ASTM C1064.
    se

    3 All concrete test specimens for strength or other purposes shall be carefully protected and
    er

    cured.
    ov

    4 Specimens shall be protected from accidental damage by plant personnel or equipment on


    Site.
    o

    5 Specimens shall be kept moist by the addition of water or covering by suitable curing
    it

    materials.
    et
    m

    6 The exact time of preparation of the specimen on Site shall be noted and the time when it is
    transferred to the laboratory. These times shall be written on the test report.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 16: Miscellaneous

    16 MISCELLANEOUS .................................................................................................. 2
    16.1 GENERAL ............................................................................................................... 2
    16.1.1 Scope 2
    16.1.2 References 2
    16.2 PAVEMENT QUALITY CONCRETE ........................................................................ 3
    16.2.1 Scope 3
    16.2.2 Mix Designs 3
    16.2.3 Cement 4
    16.2.4 Water 4
    16.2.5 Aggregates 5
    16.2.6 Admixtures 5
    16.2.7 Air content 5

    .
    16.2.8 Density 5

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    16.3 CEMENTITIOUS GROUT ........................................................................................ 6

    rw
    16.3.1 General 6
    16.3.2 Material 6
    16.3.3 Workmanship 6
    16.4 ta
    SCREEDS ............................................................................................................... 7
    qa
    16.4.1 Scope 7
    16.4.2 General 7
    as

    16.5 CELLULAR CONCRETE ......................................................................................... 9


    16.6 REPAIR OF CONCRETE ........................................................................................ 9
    se

    16.6.1 General 9
    16.6.2 Honeycombing or Spalling 9
    er

    16.6.3 Crack injection 11


    ov

    16.7 POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NON-


    PRESSURE DRAINAGE AND SEWERAGE ......................................................... 13
    o

    16.7.1 General 13
    it

    16.7.2 Resin 13
    et

    16.7.3 Minimum strength 14


    m
    QCS 2014 Section 05: Concrete Page 2
    Part 16: Miscellaneous

    16 MISCELLANEOUS

    16.1 GENERAL

    16.1.1 Scope

    1 This Part deals with miscellaneous items related to concrete works including pavement
    quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair
    of concrete and guniting.

    2 Related Sections and Parts are as follows:


    This Section
    Part 2, .............. Aggregate

    l .
    Part 3, .............. Cementitious Material

    .l.
    Part 4, .............. Water

    rw
    Part 5, .............. Admixture
    Part 6, .............. Property Requirements
    Part 7, .............. Concrete Plants

    ta
    Part 8, .............. Transportation and Placing of Concrete
    Part 9, .............. Formwork
    qa
    Part 10, ............ Curing
    Part 15, ............ Hot Weather Concreting.
    as

    16.1.2 References
    se

    1 The following standards are referred to in this Part:


    er

    ACI 506, .....................Guide to Shotcrete


    ASTM C989 10, ........Standard Specification for Slag Cement for Use in Concrete and
    ov

    Mortars
    BS 146,.......................Portland-blast furnace cement
    o

    BS 812,.......................Testing aggregates
    it

    BS 1881,.....................Testing concrete
    et

    BS 2782,.....................Methods of testing plastics


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    BS 3892,.....................Pulverised fuel ash


    BS 4551,.....................Methods of testing mortars, screeds and plasters
    BS 5075,.....................Concrete admixtures
    BS 6319,.....................Testing of resin and polymer / cement compositions for use in
    construction
    BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement.
    BS 8203,.....................Code of practice for installation of resilient floor coverings.
    BS 8500,.....................Concrete
    BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for
    common cements
    BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2,
    4, 5, 6, 8, 10, 11, and 12)
    BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6)
    BS EN 998,.................Specification for mortar for masonry
    QCS 2014 Section 05: Concrete Page 3
    Part 16: Miscellaneous

    BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis


    BS EN 12350,.............Testing fresh concrete
    BS EN 12390-5, .........Flexural strength of test specimens
    BS EN 12620,............. Aggregates for concrete

    EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low


    early strength blastfurnace cements
    EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low
    early strength blastfurnace cements
    EN 12350, ..................Testing fresh concrete
    EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis
    GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

    .
    SHW 1000 ..................Specification for Highway Works UK ROAD PAVEMENTS

    l
    .l.
    CONCRETE MATERIALS

    rw
    16.2 PAVEMENT QUALITY CONCRETE

    16.2.1 Scope
    ta
    qa
    1 This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as
    surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement
    bound granular material used as a roadbase or sub-base or as a backfill material for
    as

    excavations.
    se

    16.2.2 Mix Designs


    er

    1 Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1
    below, in accordance, with the pavement design shown on the Drawings or as directed by the
    ov

    Engineer.
    o

    2 All concrete for use in pavements shall be designed mixes or equivalent standard mixes in
    it

    accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where
    et

    otherwise specified.
    m

    3 Prescribed mixes may be used for rapid construction with the approval of the Engineer.

    Table 16.1
    Pavement Grades
    BS 8500 and
    BS 8500 and
    GSO EN 206-
    Pavement Layer GSO EN 206-1
    1Designed
    Standard Mix
    Mix
    Surface Slabs
    Unreinforced Concrete C40
    Jointed Reinforced Concrete ( JRC ) C40
    Continuously Reinforced Concrete Pavement ( CRCP ) C40
    Continuously Reinforced Concrete Roadbase ( CRCR ) C40
    Ground Anchorage Beam C40
    QCS 2014 Section 05: Concrete Page 4
    Part 16: Miscellaneous

    BS 8500 and
    BS 8500 and
    GSO EN 206-
    Pavement Layer GSO EN 206-1
    1Designed
    Standard Mix
    Mix

    Wet Lean Mix Concrete 4 C20 ST4


    Wet Lean Mix Concrete 3 C15 ST3
    Wet Lean Mix Concrete 2 C10 ST2
    Wet Lean Mix Concrete 1 C7.5 ST1

    16.2.3 Cement

    1 The general term 'cement' in this Part means the materials shown below.

    l .
    .l.
    Cement Complying with

    rw
    Cement. Composition, specifications and conformity criteria for EN 197-1
    common cements
    Portland blast furnace cement BS 146 or EN 197-4

    ta
    Specification for pozzolanic pulverised-fuel ash cement (grades BS 6610
    qa
    C20 or below)
    as

    2 The use of a combination of Portland cement and ground granulated blast furnace slag is
    permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate
    the minimum combined cementitious material content required for the mix.
    se

    3 The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted
    er

    subject to the approval of the Engineer. In such cases, the Engineer will stipulate the
    ov

    minimum combined cementitious material content required for the mix. PFA shall be in
    accordance with BS 3892.
    o

    4 The use of microsilica in the mix designs will be permitted if approved by the Engineer.
    it
    et

    5 The Engineer will stipulate the minimum combined cementitious material content required for
    the mix where PFA or GGBFS are used.
    m

    6 The maximum proportion of ground granulated blastfurnace slag with Portland cement shall
    be as per Table 6.6 of Part 5.6.

    7 In combination with Portland cement, the proportion of PFA by mass to the total cement shall
    be as per Table 6.6 of Part 5.6.

    8 The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

    9 The minimum cement content for concrete pavements shall be preapproved by Qatar
    Standards.

    16.2.4 Water

    1 Water for use in the making and curing of concrete shall conform to the requirements of Part
    4 of this Section.
    QCS 2014 Section 05: Concrete Page 5
    Part 16: Miscellaneous

    2 The water content shall be the minimum required to provide the agreed workability for full
    compaction of the concrete to the required density, as determined by trial mixes or other
    means approved by the Engineer..

    16.2.5 Aggregates

    1 The requirements of Part 2 of this specification will govern, except as modified below.

    2 Aggregates for all pavement concrete shall be complying with BS EN 12620

    3 Alternatively coarse aggregate of recycled and secondary aggregate materials may be used
    to replace up to 50% by mass of coarse aggregate

    4 The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between
    longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not

    l .
    exceed 20 mm.

    .l.
    rw
    5 If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate
    combination to check for the possibility of alkali silica reaction. Such tests shall be carried out
    in accordance with the procedure laid down in Part 2 of this Section.

    16.2.6 Admixtures ta
    qa
    1 Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN
    as

    934. Admixtures containing calcium chloride shall not be used.

    2 Other chloride-free admixtures may be used with the approval of the Engineer.
    se

    16.2.7 Air content


    er
    ov

    1 The total quantity of air in air-entrained concrete as a percentage of the volume of the mix
    shall be 5 1.5 % for mixes of nominal aggregate size 20 and be 4 1.5 % for mixes of
    nominal aggregate size 40.
    it o

    2 The air content shall be determined at the point of delivery by a pressure type air meter in
    et

    accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at
    least six times per day whichever is the greater, in conjunction with tests for workability and
    m

    strength. For areas less than 300 m2, the rate shall be at least one determination to each 20
    m length of slab or less constructed at one time or at least three times per day. If the air
    content is outside the specified limits, a further determination shall be made immediately on
    the next available load of concrete before discharging. If the air content is still outside the
    limit, the Contractor shall immediately adjust the air content of the concrete to improve its
    uniformity, before further concrete is used in the Works.

    3 The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing
    the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure
    uniform distribution of the agent throughout the batch during mixing.

    16.2.8 Density

    1 The density of concrete Grades greater than C30 shall be such that without air-entrainment
    the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not
    more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.
    QCS 2014 Section 05: Concrete Page 6
    Part 16: Miscellaneous

    2 The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the
    theoretical maximum dry density.

    16.3 CEMENTITIOUS GROUT

    16.3.1 General

    1 This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be
    used to where it is necessary to eliminate shrinkage when filling the void between a base
    plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including
    masts, anchor bolts and fence posts.

    2 The grout shall be supplied by a reputable construction chemical company as a single pack
    prepackaged cement based product which is chloride free.

    l .
    3 For a particular application, the Contractor shall submit a method statement detailing how the

    .l.
    formwork will be placed and the points where the grout will be poured.

    rw
    4 Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of
    the materials and methods with the suppliers representative being present to train the

    ta
    Contractors personnel in the correct use of the material.
    qa
    16.3.2 Material
    as

    1 The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing
    and non shrink.
    se

    2 Positive volumetric expansion shall take place while the grout is plastic by means of gaseous
    er

    expansion to avoid shrinkage and cracking.


    ov

    3 The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall
    be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.
    o

    4 The grout shall exhibit a high early strength gain yet not be subject to cracking or other
    it

    detrimental effects.
    et

    5 At ambient temperatures above 35 C, cool water shall be used for mixing the grout before
    m

    placing.

    16.3.3 Workmanship

    1 The storage handling and pouring of the grout shall be in strict accordance with the
    manufacturers instructions.

    2 The substrate surface shall be free from oil grease or loose or partially bonded material.

    3 If the concrete surface is defective or has laitance it shall be cut back to a sound base.

    4 Bolt holes and fixing pockets shall be blown clean of dirt or debris.

    5 The substrate shall be soaked with fresh potable water before grouting, although immediately
    before grouting, free water shall be removed and blown out of bolt holes or pockets.
    QCS 2014 Section 05: Concrete Page 7
    Part 16: Miscellaneous

    6 Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide.
    For larger base plates or flow areas the manufacturers instructions shall be followed.

    7 Base plates and metallic items shall be clean and free from oil, grease, or scale.

    8 Vent holes shall be provided to allow the release of air from isolated spots.

    9 Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between
    the constructive formwork and joints. Formwork shall extend above the required pour height
    and if necessary shall be extended to allow a hydrostatic head to aid placement.

    10 The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

    11 The quantity of water to be added to the preweighed bags shall be enough to give the
    desirable consistency as trowelable or flowable.

    l .
    .l.
    12 Mixing shall take place for a minimum of 5 min.

    rw
    13 The grout shall be placed within the time limit specified by the manufacturer depending on
    the actual application temperature.

    14 ta
    Grout shall be poured from one side and it shall be verified that the grout has flowed under all
    qa
    of the base plate with no voids. Pouring from several sides shall not be permitted.

    15 Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.
    as

    16.4 SCREEDS
    se

    16.4.1 Scope
    er
    ov

    1 This Subpart covers screeds that provide by means of a layer of mortar a level surface in
    flooring applications and to provide falls on flat concrete roofs.
    o

    16.4.2 General
    it
    et

    1 Screeds shall be suitable for application onto a concrete substrate.


    m

    2 The screeds shall be suitable for receiving surface finishes which may arrange from thin
    flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

    3 Screed mortars shall generally comprise sand and cement modified by additives or
    substituted by other materials such as polymers in order to provide specific performance
    requirements.

    4 For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of


    10 mm aggregate.

    5 Aggregates used for screeds shall not contain deleterious materials such as coal or iron
    particles which may affect the finish the surface of the screed.

    6 Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening
    and shall comply with the appropriate part of BS EN 480 and BS EN 934.
    QCS 2014 Section 05: Concrete Page 8
    Part 16: Miscellaneous

    7 Polymer based additives may be used to improve adhesion and strength of thin or featured
    screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or
    acrylic polymers.

    8 Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

    9 Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used
    strictly in accordance with the manufacturers instructions.

    10 The interface of the screed in the concrete substrate shall be specified as one of the
    following options by the Engineer:

    (a) Monolithic with the concrete base: The screed shall be applied within 3 hours of
    placing the concrete base.
    (b) Bonded to the concrete base: Screed shall be laid onto a concrete base which is

    l .
    hardened and is subsequently been prepared to receive the screed, the minimum

    .l.
    thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

    rw
    (c) As an unbonded screed: The screed shall be laid on a separating layer.
    (d) As a floating screed: The screed shall be laid on an insulating material.

    11 ta
    The cement and sand screed mix shall have the minimum amount of water added to give
    qa
    sufficient workability and allow the material to be thoroughly compacted.
    as

    12 Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate
    ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water
    se

    and admixtures shall ensure a thorough homogeneous mixture with no balling up of the
    cement.
    er

    13 Screeds shall be laid either between carefully levelled and trued batons or between strips of
    ov

    screed laid and compacted to a finished level.

    14 For bonded screed where a high degree of bond is required the surface laitance of the
    o

    concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer
    it

    of neat cement grout shall be applied to the prewetted or dampened concrete and the screed
    et

    applied and compacted while the grout is wet.


    m

    15 Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints
    around the perimeter shall be particularly well compacted to avoid breaking out and curling.

    16 Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be
    kept protected by waterproof sheeting for at least 7 days after laying.

    17 Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and
    necessary strength achieved.

    18 If requested by the Engineer the Contractor shall carry out a soundness and impact test in
    accordance with BS 8203.

    19 Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction
    or movement joints shall be provided as appropriate, where shown on the drawings or as
    directed by the Engineer. Bays shall be laid alternatively.
    QCS 2014 Section 05: Concrete Page 9
    Part 16: Miscellaneous

    20 Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick
    screed.

    16.5 CELLULAR CONCRETE

    1 Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is


    exchanged for an insulation medium, namely air, embedded in an organic and bio-
    degradable foam. It behaves, like conventional concrete, in particular concerning curing,
    hardening and most important "ageing ". CC infinitely increases its strength by hydration as
    long as exposed to humidity in the atmosphere.

    2 CC offer more thermal insulation and a substantially higher fire-rating than conventional
    concrete.

    3 Minimum compressive strengths shall be 4.0 MPa.

    l .
    .l.
    4 The required density and strength of the CC shall be specified on the drawings and approved

    rw
    by the Engineer.

    5 The method of production of Cellular Concrete shall be shown on the drawings or directed by

    ta
    the Engineer. The Contractor shall submit full technical details of the materials and method of
    qa
    production for the CC along with a list of previous projects where the particular system has
    been used.
    as

    6 After source approval of the material and system the Contractor shall submit a mix design for
    the CLC for the approval of the Engineer. After the review and approval of the mix theoretical
    se

    mix design the Contractor shall carry out a trial mix to check the workability of the fresh
    concrete and to allow samples to be made for compressive strength and density.
    er

    7 The Engineer may also instruct that tests are carried out for abrasion resistance and thermal
    ov

    insulation properties.

    8 Cellular Concrete shall not be used for structural reinforced members.


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    16.6 REPAIR OF CONCRETE


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    16.6.1 General

    1 The extent and nature of the defects in concrete shall be established in accordance with Part
    15 of this Section. Based on these results the Engineer shall confirm the acceptability of the
    work and whether remedial works are required.

    2 If remedial works are required the Contractor shall submit a detailed method statement
    identifying the specific materials to be used and the sequence of activities for the repair.

    3 Only proprietary proven materials that form part of a standard repair system shall be used.

    16.6.2 Honeycombing or Spalling

    1 Where there is honeycombed concrete or concrete damaged by physical forces such as


    impact that has caused spalling, the concrete shall be replaced using a high strength free
    flowing cementitious micro-concrete.

    2 The areas of repair shall be marked out and agreed with the Engineer.
    QCS 2014 Section 05: Concrete Page 10
    Part 16: Miscellaneous

    3 All honeycombed, loose, cracked or friable concrete in these areas shall be removed until
    sound concrete is reached. Due account shall be taken of propping or other instructions
    given by the Engineer regarding sequences of removal and repair.

    4 The equipment and methods used to break out the concrete shall be such that no reinforcing
    steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened
    or damaged unless so directed by the Engineer.

    5 Where the removal of concrete by mechanical means is difficult due to reinforcement


    congestion, then the use of high pressure water jetting shall be considered and necessary
    provisions for protecting the rest of the structure shall be made.

    6 The prepared void shall be profiled so that entrapment of air is avoided during the repair
    process using fluid micro-concrete.

    7 The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be

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    repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be

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    accepted.

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    8 The prepared concrete surface shall be sound and clean and free of loose particles, dust and
    debris.

    9 ta
    Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose
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    millscale.

    10 Reinforcement damaged during the removal of concrete or the preparation process shall, if
    as

    required by the Engineer, be repaired or replaced.


    se

    11 Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall
    be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair
    er

    material without distortion or movement during placement.


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    12 The formwork shall be watertight at all joints between panels and between the formwork and
    the existing concrete surface so as to prevent grout leakage.
    o

    13 The formwork shall be constructed from appropriate materials as agreed with the Engineer to
    it

    achieve the required finish.


    et

    14 Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated
    m

    with a suitable mould release agent. This shall be used in accordance with the
    manufacturer's recommendations.

    15 The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient
    hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled
    completely and no air remains entrapped.

    16 Where necessary, provision shall be made for controllable bleed points to prevent air
    entrapment and enable the extent of flow of the repair material to be assessed.

    17 The formwork shall be inspected by the Engineer and, if approved, filled with clean water
    which demonstrates that the formwork is grout-tight and saturates the prepared concrete
    surfaces. The formwork shall be then be completely drained and resealed

    18 In situations where the completed repair will be subjected to constant immersion an epoxy
    bonding agent shall be applied in accordance with the manufacturers instructions.
    QCS 2014 Section 05: Concrete Page 11
    Part 16: Miscellaneous

    19 Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18
    and tested at 20 oC

    20 The thermal conductivity and the elastic modulus of the repair material shall be compatible
    with the host concrete.

    21 If requested by the Engineer, recent test results of the material for the following properties
    shall be submitted:

    (a) thermal conductivity


    (b) elastic modulus, BS 1881
    (c) expansion characteristics, ASTM C 827, CRD 621-82A
    (d) flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

    22 The micro-concrete shall be mixed and placed in accordance with the manufacturer's

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    recommendations, particularly with regard to water content, mixing equipment and placing

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    time.

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    23 As far as possible the placing of the micro-concrete shall be continuous. The mixing
    operation shall be timed so that there is minimal interruption in the material flow. If, however,

    ta
    placing is interrupted, the operation shall recommence as soon as possible while the repair
    material retains its flow characteristics.
    qa
    24 The formwork shall not be removed until the repair micro-concrete has achieved a
    compressive strength of at least 10 MPa or as directed by the Engineer.
    as

    25 Immediately after removal of the formwork the repair area shall be cured in accordance with
    se

    Part 10 of this Section.


    er

    26 The repair material shall:

    (a) be shrinkage compensated in both liquid and cured states


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    (b) contain no metallic expansion system


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    (c) be prepacked and factory quality controlled


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    (d) be a free-flowing cementitious material that has a coefficient of thermal expansion fully
    et

    compatible with the host concrete and which complies with the requirements of Table
    16.3.
    m

    Table 16.3
    Property requirements of micro concrete

    Property Test Method Minimum Value

    Compressive strength BS EN 12390-3 @ 28 d 50 MPa


    Flexural strength BS 4551 @ 28 d 10 MPa
    Anchorage bond BS 8110 Passes

    16.6.3 Crack injection

    1 This clause of the specification covers non-active cracks within concrete elements caused by
    shrinkage or other structural movement. Non-active cracks shall be injected with a low-
    viscosity epoxy resin to fill and seal the crack and restore the structural integrity.
    QCS 2014 Section 05: Concrete Page 12
    Part 16: Miscellaneous

    2 Before to starting the injection operation it shall be established by testing and investigation
    work that cracks manifest within concrete elements due to either or both shrinkage or
    structural movement are non-active.

    3 The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be
    filled shall be marked out in detail on the concrete elements by the Contractor and agreed
    with the Engineer before proceeding.

    4 The extent of the work may be adjusted by the Engineer as the project proceeds, according
    to the conditions found.

    5 Grease, oil or other contaminants shall be removed. Algae and other biological growth shall
    also be removed by scrubbing with bactericide or detergent and clean water. If necessary,
    wire brushes shall be used.

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    6 Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within

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    the marked out scope of the work shall be removed.

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    7 All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the
    concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

    8 ta
    The injection nipples shall be fixed at intervals along the length of each crack. The distance
    qa
    between each nipple will depend on the width and depth of the crack.
    as

    9 Spacing shall be close enough to ensure that the resin will penetrate along the crack to the
    next point of injection. This will normally be between 200 mm and 100 mm.
    se

    10 Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant
    shall be supplied in two pans (liquid base and hardener system). The two components shall
    er

    be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.


    ov

    11 The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall
    be pressed firmly into place and held for several seconds until secure. The mixed sealant
    o

    shall be applied around each embedded nipple, ensuring a complete seal is made. In this
    it

    way, all the nipples shall be fixed along the length of the crack.
    et

    12 In the case of a wall or slab which is cracked all the way through, nipples shall be located on
    m

    both sides with those at the back placed at midway points between those it the front.

    13 The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to
    40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or
    slab shall be sealed in this way.

    14 The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures
    (5 C to 12 C) the curing time will be extended and the Contractor shall ensure that the
    surface sealant has adequately cured before continuing.

    15 One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to
    either end of horizontal cracks.

    16 Each crack shall be treated in a single, continuous operation. Sufficient material shall
    therefore be made ready before the commencement of the work.
    QCS 2014 Section 05: Concrete Page 13
    Part 16: Miscellaneous

    17 The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of
    the mixed material.

    18 The preparation, mixing and application of the materials shall be undertaken in strict
    accordance with the manufacturer's recommendations. The Contractor is to ensure that all
    necessary tools and equipment are on Site.

    19 Both the compressive strength and flexural strength shall be tested at 7 d.

    20 The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the
    failure shall be in the concrete and not at the interface.

    21 The injection resin shall be of a prepackaged or preweighed type and only the use of full units
    will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

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    22 In all operations of storage, mixing and application, the Contractor shall comply with the

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    health and safety recommendations of the manufacturer and governing authorities.

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    23 The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this
    time.

    24 ta
    The nipples and bands of surface sealant shall then be removed and damaged areas made
    qa
    good to the satisfaction of the Engineer.

    25 The injection material shall be compatible with the host concrete and shall have the
    as

    properties shown in Table 16.4 when tested in accordance with the relevant standards.
    se

    Table 16.4
    Property Requirement for Epoxy Crack Injection Material
    er

    Property Method Minimum Value


    ov

    Compressive strength BS 4551, BS 2782 BS 6319 70 MPa


    Flexural strength BS EN 12390-5
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    16.7 POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NON-


    et

    PRESSURE DRAINAGE AND SEWERAGE


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    16.7.1 General

    1 Polyester resin concrete is a mixture formed from aggregates and fillers which are bound
    together using a polyester resin (also called Polymer concrete pipes), as defined in ISO
    18672-1 or ASTM D 6783 with the amendments given below.

    2 Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems
    (pipes, manhalls, soakways).

    16.7.2 Resin

    1 The resin used in the pipe system and manufactured as per ISO 18672-1shall have a
    temperature of deflection of at least 85 C, when tested in accordance with Method A of
    ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the
    applicable requirements of EN 13121-1.
    QCS 2014 Section 05: Concrete Page 14
    Part 16: Miscellaneous

    2 The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a
    minimum deflection temperature of 85C when tested at 1.82 MPa following Test Method
    D648. The resin content shall not be less than 7 % of the weight of the sample as determined
    by Test Method D2584.

    16.7.3 Minimum strength

    1 The minimum strength classes for different pipe shapes are given below.
    Table 16.4

    Minimum strength classes for pipes designated PRC-OC or PRC-TC


    Strength class
    Nominal size Sc
    DN N/mm

    .
    PRC-OC PRC-TC

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    150 DN 500 180 180

    rw
    600 DN 1000 145 160
    1200 DN 3000 120 145

    ta
    qa
    Table 16.5
    Minimum strength classes for pipes designated PRC-OE or PRC-TE
    as

    Strength class
    Nominal width/height Sc
    WN/HN
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    N/mm
    er

    PRC-OE PRC-TE
    ov

    300/450 WN/HN 600/900 180 180


    700/1050 WN/HN 1000/1500 145 160
    o

    1200/1800 WN/HN 1400/2100 120 145


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    et

    Table 16.6
    m

    Minimum strength classes for pipes designated PRC-OK or PRC-TK


    Strength class
    Sc
    Nominal size
    DN N/mm
    PRC-OK PRC-TK
    800 DN 1000 145 160
    1200 DN 1800 120 145

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 7
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 8
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 9
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 10
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 11
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 12
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 13
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 14
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 15
    Part 15: Appendix B - Templates

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 16
    Part 15: Appendix B - Templates

    15.2 CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 17
    Part 15: Appendix B - Templates

    15.3 QUALITY NON-CONFORMANCE TEMPLATE

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    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 02: Submittals

    2 SUBMITTALS .......................................................................................................... 2
    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Project Quality Plan 2
    2.1.2 Quality Organisation Plan 3
    2.1.3 Inspection and Test Plans 4
    2.1.4 Quality Checklists 5
    2.1.5 Key Performance Indicators 5
    2.1.6 Method Statements 6
    2.1.7 Commissioning Plan 6

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 02: Submittals

    2 SUBMITTALS

    2.1 GENERAL

    2.1.1 Project Quality Plan

    1 The Contractor shall prepare the necessary Contract specific Project Quality Plan as
    specified in this Section, the Contract Documents and as a minimum meeting the
    requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and
    approval within 30 days of the award of Contract. The Contractor is not permitted to Work on
    the worksite until such time as the plan has been approved by the Engineer.

    2 The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor
    shall undertake a full formal review of the quality plans annually with reference to the date of

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    award of the Contract and submit the findings of the review to the Engineer within 14 days of

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    that date along with an amended plan should any amendments be required.

    rw
    3 The Project Quality Plan shall describe the Contractors Quality Management System that will
    be used throughout the Contract and the contents shall include but not be limited to the
    following:
    ta
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    (a) Front Cover
    (b) Table of Contents
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    (c) Project Scope, Requirements and Quality Objectives


    se

    (d) Quality Policy and ISO 9001 Certificate (if applicable)


    (e) Control of Project Quality Plan
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    (f) Reference Documentation


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    (g) Project Management, Planning and Resources


    (h) Management, Organisation and Responsibilities
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    (i) Contract Review


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    (j) Project Deliverables


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    (k) Communication with the Engineer


    (l) Management of Documents, Data and Records
    (m) Design (Including Temporary Works)
    (n) Procurement of Services, Equipment and Materials
    (o) Method Statements
    (p) Inspection and Test
    (q) Product Identification and Traceability
    (r) Owner Supplied Product
    (s) Handling, Storage, Packaging and Delivery
    (t) Non-conformance, Corrective and Preventative Action
    (u) Control of Inspection, Measuring and Test Equipment
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 02: Submittals

    (v) Audits
    (w) Training
    (x) Key Performance Indicators and Continual Improvement
    (y) Management Review
    (z) Quality Meetings
    (aa) Monthly Quality Report
    (bb) Commissioning
    (cc) Interface Management
    (dd) Project Completion and Handover
    (ee) Appendices

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    4 And include as a minimum:

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    (a) a detailed description of procedures, instructions, and reports to be used to ensure
    compliance with the Project Documentation
    (b) a detailed description of procedures for reviewing shop drawings, samples, certificates
    ta
    and other submittals necessary for compliance with the Project Documentation
    qa
    (c) a detailed description of procedures used to identify, report and resolve problems
    (d) a description of the services provided by outside organisations such as testing
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    laboratories, architects, and consulting engineers


    (e) a detailed description of inspections and tests required
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    (f) copies of forms and reports to be used to document quality assurance operations
    er

    (g) the names of personnel responsible for each part of the Works
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    (h) a submittal status log listing required submittals and action required by the Contractor
    and Engineer
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    (i) a detailed description of document and submittal control procedures


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    (j) an inspection and test schedule keyed to the construction programme


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    (k) procedures to identify and control the use of items and materials
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    5 No construction shall begin and no requests for payment from the Contractor shall be
    processed until the Contractors Project Quality Plan is approved.

    6 A Contractors Project Quality Plan Template with guidance notes is included in Part 15
    Appendix B of this Section. The format of the Contractors Project Quality Plan must follow
    this template including all clauses contained within.

    2.1.2 Quality Organisation Plan

    1 The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later
    than thirty (30) days from the start of the Contract.

    2 The Quality Organisation Plan shall provide the names, qualifications, experience and skills
    of all the QA/QC Team including Corporate QA/QC Manager, Quality Management
    Representative and key support staff.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 02: Submittals

    3 The Quality Organisation Plan shall show the organisation of Contractors quality team and
    shall include, but not be limited to, the following:

    (a) an organisation chart identifying all personnel responsible for quality


    (b) Identify the quality team showing that the team is independent of the job supervisory
    staff with clear lines of authority to top tier management.
    (c) Indicate and describe the area of responsibility and authority of each individual in the
    quality assurance team.

    4 The Quality Organisation Plan should also define quality responsibilities of any of the
    Contractors team with responsibilities under the Contractors Project Quality Plan.

    5 The Contractors Quality staff shall have relevant educational and professional qualifications,
    and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of

    .
    the works at the worksite until such time as approved quality personnel have been deployed

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    on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed
    quality personnel without prior approval from the Engineer.

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    6 The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a

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    standalone document and cross-referenced within the Project Quality Plan.
    qa
    2.1.3 Inspection and Test Plans

    1 As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan
    as

    Schedule to the Engineer for approval no later than thirty (30) days from the start of the
    Contract.
    se

    2 The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be
    er

    prepared for the Works and the target dates for their submission to the Engineer for his
    approval.
    ov

    3 The Inspection and Test Plans shall consider the requirements of each Section of the
    o

    Specification and shall identify, as a minimum, the following:


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    (a) Details each activity, inspection and test to be performed


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    (b) Reference to specifications, standards etc.


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    (c) the required inspection and testing frequency


    (d) the acceptance/rejection criteria
    (e) whom from the Contractors team is responsible and qualified to perform the inspection
    or test
    (f) Quality Records to be generated
    (g) Hold, Witness, surveillance and Record Review points of the Contractors team, the
    Engineer and any other agencies having jurisdictional authority over the work relating
    to each inspection and test to be performed.

    4 Each inspection and test shall have a unique reference number.

    5 Inspection and Test Plans are required to address the Contractors on and off site Work and
    preparation, submission and approval of related documentation.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 02: Submittals

    6 Inspection and Test Plans are required for all operations including major temporary works
    and commissioning.

    7 No work covered by the Inspection and Test Plan shall begin until the plan has been
    approved by the Engineer.

    8 A Contractors Inspection and Test Plan Template with guidance notes is included in
    Appendix B of this Section and must be used by the Contractor

    2.1.4 Quality Checklists

    1 The Contractor shall develop specific quality checklists for all activities to be checked as per
    the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection
    Test Plans submission prior to the start of the activity.

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    2 The Contractor shall inspect the work and sign off the relevant checklist and Inspection

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    Request prior to the final inspection with the Engineer.

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    3 The checklist shall be attached with the Inspection Request and other relevant attachments
    and submitted to the Engineer.

    2.1.5 Key Performance Indicators ta


    qa
    1 The Contractor shall develop and report Key Performance Indicators (KPIs). KPIs are a set
    as

    of quantifiable measures that are used to gauge performance of the Contractors


    Performance.
    se

    2 The KPIs shall be defined in the Contractors Project Quality Plan and be subject to
    Engineers approval.
    er

    The Contractor is responsible for developing his own KPIs for all elements of his contract
    ov

    3
    (Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPIs.
    o

    (a) Time between identification of a Nonconformance or Corrective Action and actual


    it

    raising on the system.


    et

    (b) Time between opening and closure of Nonconformance Reports (NCR) and Corrective
    Action Requests (CAR).
    m

    (c) NCR and CAR statistics per areas, sections, discipline, subcontractor etc.
    (d) Percentage of reoccurring NCRs and CARs Trends on NCRs and CARs.
    (e) Approval status of critical documentation for the progress of the works (Method
    Statements, ITPs etc.).
    (f) Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed,
    pass first time, etc.).
    (g) Completion packages (As-Built folders) progress.

    4 Reporting of the KPIs shall include a graphical bar chart representation on a month by month
    basis from the start of the Contract.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 6
    Part 02: Submittals

    2.1.6 Method Statements

    1 Contractor shall ensure that Method Statements address quality issues. Refer to Section 11
    Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in
    particular section 2.4

    2.1.7 Commissioning Plan

    1 The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than
    sixty (60) days unless agreed otherwise with the engineer before the start of the
    commissioning of the Works or any part thereof.

    2 The Commissioning Plan shall consider the requirements of each Section of the Specification
    in turn and shall identify the following:

    .
    (a) all required commissioning work required by that Section of the Specification

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    (b) any prerequisites to commissioning

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    (c) a list of the commissioning procedure
    (d) a detailed description of the duties and responsibilities on the personnel involved in the
    commissioning process
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    (e) a detailed list of the tests/checks/activities that will be performed, linked to the relevant
    construction activities and referenced to any links/documents to the ITPs performed
    during the construction
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    (f) specific reference to the witness/hold and review points of the engineer
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    (g) a detailed list of the standards /specifications/regulatory requirements that need to be


    performed
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    (h) a detailed description of the interactions/communication between different


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    organization/public service or other legal/regulatory institutions


    (i) a detailed description of the test/activities of the maintenance needed during the life
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    time of the project, with reference to any special requirements/qualifications of the


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    personnel involved in the maintenance activities


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    (j) a detailed description of any spare parts/equipment/fixtures and other type of the of
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    consumables that might be needed, with an estimation of quantities, for the life time of
    the project
    (k) a detailed description of the as built project file that will be created after the
    commission phase
    (l) a procedure for up-date and revision of the commissioning plan

    3 No work covered by the Commissioning Plan shall begin until the plan has been approved.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 03: Contractors Quality Personnel

    3 CONTRACTORS QUALITY PERSONNEL ............................................................. 2


    3.1 INTRODUCTION ..................................................................................................... 2
    3.1.1 General 2
    3.1.2 Quality Assurance Manager 2
    3.1.3 Quality Control Manager 2
    3.1.4 Quality Engineer 2
    3.1.5 Quality Inspector 3
    3.1.6 Personnel Qualifications 3
    3.1.7 Quality Staff Requirement 3
    3.1.8 Quality Training for Contractors Employees and Labour 5

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 03: Contractors Quality Personnel

    3 CONTRACTORS QUALITY PERSONNEL

    3.1 INTRODUCTION

    3.1.1 General

    1 Contractor shall, throughout the execution and completion of the Works and the remedying
    defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only
    with matters regarding the quality and protection against damage before, during and after
    execution of Works as specified in this section. This team shall be qualified and experienced
    in their work and shall have the authority to issue instructions and shall take protective
    measures to prevent execution of Works that do not comply with the Specifications.

    2 The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any

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    of the quality team designated in the Quality Organisation Plan.

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    3 The Contractor shall have adequate quality personnel on the site during all production
    operations, including adequate coverage during night shift operations and off site work.

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    The Contractor's quality team shall have the authority to stop any portion of the work which
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    does not comply with the requirements of the Project Documentation.

    5 Minimum qualifications and experience of the Contractors Quality Personnel shall be as


    as

    defined in the Contract.


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    3.1.2 Quality Assurance Manager


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    1 Where required by this section, the Contractor shall designate and assign a full time Quality
    Assurance Manager who shall be responsible for overseeing the implementation and
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    operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report
    directly to Top Tier Management and be independent of the Contractors organisation
    responsible for construction.
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    3.1.3 Quality Control Manager


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    1 Where required by this section, the Contractor shall designate and assign a full time Quality
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    Control Manager who reports directly to the Quality Assurance Manager and shall be
    responsible for supervision of the construction quality control management activities and
    ensuring compliance with the Contractors Inspection and Test Plans and associated
    specification and contract documentation.

    3.1.4 Quality Engineer

    1 Where required by this section, the Contractor shall designate and assign a Quality Engineer
    who reports directly to the Quality Assurance Manager or Quality Control Manager and shall
    be responsible for assisting them with their day to day responsibilities and may be
    assigned to cover several locations or areas of work relating to the Contract. Where a Quality
    Assurance Manager or Quality Control Manager are not required by this section the Quality
    Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 03: Contractors Quality Personnel

    3.1.5 Quality Inspector

    1 The Contractor shall designate and assign a Quality Inspector for each shift for each location
    where work is being performed. Each Quality Inspector shall be qualified by training and
    experience in all the construction or fabrication activities being conducted at the location of
    work and is directly responsible for ensuring compliance with the Contractors Inspection and
    Test Plans and associated specification and contract documentation.

    3.1.6 Personnel Qualifications

    1 The Contractor shall identify activities requiring qualified production, inspection, and test
    personnel and establish their minimum competence level.

    2 The Contractor shall maintain records of personnel qualifications as quality records.

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    3.1.7 Quality Staff Requirement

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    1 Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified
    quality personnel for the Work as per below tables.

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    Quality Staff Requirement
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    No No of workers on Worksite Requirement
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    1 Quality Inspector (Part time, 15 hours of duty per


    1. Less than 10
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    week)
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    2. More than 11 but less than 50 1 Quality Inspector


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    1 Quality Engineer and


    3. More than 51 but less than 500
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    1 Quality Inspector per 100 workers


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    1 Quality Assurance Manager and


    4. More than 501 but less than 1500 1 Quality Engineer per 500 workers and
    1 Quality Inspector per 100 workers

    1 Quality Assurance Manager and


    1 Quality Control Manager and
    5. More than 1501
    1 Quality Engineer per 500 workers and
    1 Quality Inspector per 100 workers
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 03: Contractors Quality Personnel

    Quality Management and Control staff Qualifications & Experience Matrix

    Minimum Qualifications Minimum Years of Minimum Key


    Position
    Required Experience Competencies

    Quality Degree in relevant 12 years, 5 of which at Qualified Professional who


    Assurance Engineering discipline and Management Level and 3 can manage a Quality
    Manager related training in Quality years Regional experience Management System and
    Management Techniques. coordinate specialised
    Internationally recognised activities. Excellent written
    Lead Auditor Certificate & verbal communication
    skills in English

    Quality Control Degree in relevant 12 years, 5 of which at Excellent written & verbal

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    Manager Engineering discipline and Management Level and 3 communication skills in

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    related training in Quality years Regional experience English
    Management Techniques.

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    Internationally recognised
    Lead Auditor Certificate
    Quality Engineer Degree in relevant
    Engineering discipline. ta
    10 years experience in
    related Quality Control
    Good written & verbal
    communication skills in
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    Internationally recognised Activities and 3 years English
    Lead Auditor Certificate Regional experience
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    Quality Inspector Certificate or Diploma in 5 years experience in Good written & verbal
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    the appropriate related Quality Control and communication skills in


    engineering discipline Materials Testing activities English
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    along with 2 years


    Regional Experience
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    2 The Contractor shall appoint deputy quality personnel who are capable of performing all the
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    duties of the quality personnel in the event of their absence.


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    3 The Contractor shall appoint support staff in sufficient numbers to ensure the effective
    function of the quality related work within the Contractors organisation.

    4 The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints
    suitably qualified quality staff to ensure the effective function of the quality related issues
    within the Sub-contractors organisation. The Sub-contractor shall appoint and deploy fulltime
    on the Worksite one Quality Inspector for every 100 workers that they employ at the
    Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality
    Engineer. This shall be in addition to the Contractors Quality Team.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 03: Contractors Quality Personnel

    3.1.8 Quality Training for Contractors Employees and Labour

    1 The Contractor shall conduct quality training including Contract specific induction, pre-work
    briefings, skills training, tool box talks and formal training conducted by training professionals
    or agencies for all the Contractors employees. The Contract specific induction will be at least
    1 hour duration, approved by the Engineer and provided for all persons involved in the
    Works. Such induction training will be reviewed, revised and repeated at intervals not
    exceeding 12 months throughout the duration of the Work. All training shall be provided in the
    languages preferred by the recipients of the training. Training shall focus on improving
    competency and skill for those performing activities that impact quality.

    2 The Contractor must conduct regular tool box talks to his Labour workforce Such training
    should include as a minimum Health and Safety issues and Construction Method best
    practice.

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    3 The Owner may organise quality related training, meetings, seminars, workshops or similar

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    events at any time throughout the Contract Period. The Contractor is required to participate

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    in such events when requested at his own expense.

    4 The Contractor shall maintain records of all training conducted including details of the training

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    given and a list of attendees, including attendees signature and ID numbers.
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    END OF PART
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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 04: Document & Data Control

    4 DOCUMENT & DATA CONTROL ............................................................................ 2


    4.1 INTRODUCTION ..................................................................................................... 2
    4.1.1 General 2
    4.1.2 Document and Data Approval and Issue 2
    4.1.3 Document and Data Changes 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 04: Document & Data Control

    4 DOCUMENT & DATA CONTROL

    4.1 INTRODUCTION

    4.1.1 General

    1 The Contractor shall establish and maintain documented procedures to control all documents
    and data that relate to the requirements of the Specification. Documents and data can be in
    the form of any type of media, such as hard copy or electronic media.

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

    4.1.2 Document and Data Approval and Issue

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    1 The documents and data shall be reviewed and approved for adequacy by authorised

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    personnel prior to issue. A master list or equivalent document control procedure identifying
    the current revision status of documents shall be established and be readily available to
    preclude the use of invalid and/or obsolete documents. This control shall ensure that:

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    The pertinent issues of appropriate documents are available at all locations where
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    operations essential to the effective functioning of the quality system are performed
    (b) Invalid and/or obsolete documents are promptly removed from all points of issue or
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    use, or otherwise assured against unintended use


    (c) Any obsolete documents retained for legal and/or knowledge preservation purposes
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    are suitably identified


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    4.1.3 Document and Data Changes


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    1 Where practicable, the nature of the change shall be identified in the document or
    appropriate attachments.
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    END OF PART
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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 05: Quality Records

    5 QUALITY RECORDS..................................................................................... 2
    5.1 INTRODUCTION ........................................................................................... 2
    5.1.1 General 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 05: Quality Records

    5 QUALITY RECORDS

    5.1 INTRODUCTION

    5.1.1 General

    1 The Contractor shall establish and maintain documented procedures for identification,
    collection, indexing, access, filing, storage, maintenance and disposition of quality records.

    2 The Contractor shall supplement these quality records as necessary to monitor quality
    throughout the Contract period.

    3 Quality records shall be maintained to demonstrate conformance of materials and equipment


    to specified technical requirements and the effective operation of the quality system.

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    4 All quality records shall be legible and shall be stored and retained in such a way that they

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    are readily retrievable in facilities that provide a suitable environment to prevent damage or
    deterioration and to prevent loss.

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    As a minimum, the quality record for any particular item shall include:
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    (a) name of item
    (b) item number
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    (c) item description


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    (d) suppliers name


    (e) serial number or other identification (where applicable)
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    (f) Specification reference (where applicable)


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    (g) verification of receipt of all required supporting documentation


    (h) quantity of items
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    (i) location and installation of item


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    (j) inspection/test procedure reference


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    (k) non-conformance number (if applicable)


    (l) Observations / comments.
    (m) Signatures of responsible person

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 06: Quality Audits

    6 QUALITY AUDITS ................................................................................................... 2


    6.1 GENERAL ............................................................................................................... 2
    6.1.1 Contractors Quality Audit 2
    6.1.2 Engineers Quality Audit 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 06: Quality Audits

    6 QUALITY AUDITS

    6.1 GENERAL

    6.1.1 Contractors Quality Audit

    1 The Contractor shall establish and maintain documented procedures in line with ISO 190011
    for planning and implementing internal quality audits to verify whether quality activities and
    related results comply with planned arrangements and to determine the effectiveness of the
    quality system.

    2 Internal quality audits shall be scheduled on the basis of the status and importance of the
    activity to be audited and shall be carried out by personnel independent of those having direct
    responsibility for the activity being audited. Unless otherwise agreed with the Engineer in

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    writing, the Contractor shall carry out a full system quality audit every three months.

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    3 The results of the audits shall be recorded and brought to the attention of the personnel
    having responsibility in the area audited. The management personnel responsible for the
    area shall take timely corrective action on deficiencies found during the audit.

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    4 Follow-up audit activities shall verify and record the implementation and effectiveness the
    corrective action taken.
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    5 The results of the Contractors quality audits shall be made available for review by the
    Engineer. The Contractor shall implement any recommendations made by the Engineer
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    based on the results of the internal audit.

    The Contractor shall allow the Engineer to observe the Contractors internal audit upon
    er

    6
    request.
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    7 Quality audits must be undertaken by suitably qualified personnel with an internationally


    recognized audit qualification to recognized standards.
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    6.1.2 Engineers Quality Audit


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    1 The Engineer may undertake a quality audit of any of the Contractors activities at any time
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    during the course of the Contract. The Contractor shall make all personnel and facilities
    available to the Engineer as necessary to undertake quality audits.

    2 The Engineer shall make the results of his quality audit available to the Contractor for review.
    The Contractor shall implement any recommendations made by the Engineer based on the
    results of the Engineers quality audit.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 07: Inspection and Test

    7 INSPECTION AND TEST ........................................................................................ 2


    7.1 INTRODUCTION ..................................................................................................... 2
    7.1.1 General 2
    7.1.2 Inspections and Tests 2
    7.1.3 Inspection and Test Status 3
    7.1.4 Inspections by the Engineer during construction 3
    7.1.5 Inspections by the Engineer during Defects Liability Period 4
    7.1.6 Workmanship 4
    7.1.7 Measuring and Test Equipment 4

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 07: Inspection and Test

    7 INSPECTION AND TEST

    7.1 INTRODUCTION

    7.1.1 General

    1 The Contractor shall provide equipment, instruments, qualified personnel, and facilities
    necessary to inspect the work and perform the tests required by the Project Documentation.

    2 The Contractor shall repeat tests and inspections after correcting non-conforming work until
    all work complies with the requirements. All re-testing and re-inspections shall be performed
    at no additional cost to the Client.

    3 The Engineer may elect to perform additional inspections and tests at the place of the

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    manufacture or the shipping point to verify compliance with applicable Specifications.

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    Inspections and tests performed by the Engineer shall not relieve the Contractor of his

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    responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be
    considered a guarantee that materials delivered at a later time will be acceptable. All costs
    associated with the foregoing shall be borne by the Contractor.

    4 ta
    Inspections and tests conducted by persons or agencies other than the Contractor, shall not
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    in any way relieve the Contractor of his responsibility and obligation to meet all Specifications
    and referenced standards.
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    7.1.2 Inspections and Tests


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    1 All inspections and tests shall be conducted in accordance with written test procedures as
    detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed
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    and approved by the Engineer.


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    2 Mandatory Products and Materials Sampling and Testing Frequencies are included in Part
    14, Appendix A of this section. The Contractor shall follow the Sampling and Testing
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    Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in
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    Appendix A shall be read and understood in tandem with the footnotes in Appendix A.
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    3 Inspection and test procedures submitted for approval shall include, but not be limited to, the
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    following:

    (a) inspection/test procedure reference


    (b) references to Clauses of this Specification and other standards along with applicable
    inspection/test levels specified therein
    (c) prerequisites for the given inspection/test
    (d) required tools, equipment
    (e) necessary environmental conditions
    (f) acceptance criteria
    (g) data to be recorded
    (h) reporting forms
    (i) Identification of items inspected and tested.
    (j) Contractors and Engineers Hold, Witness, Surveillance and Record Review Points
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 07: Inspection and Test

    4 Approved procedures and instructions shall be readily available and used by inspection and
    test personnel at the time of inspection or test. All revisions to these procedures and
    instructions shall be approved prior to being used to inspect or test the work. No deviations
    from the approved procedures and instructions shall be allowed without written authorisation
    from the Engineer.

    5 Inspection and testing work shall be performed by personnel designated by the Contractor.
    Such personnel shall not be the same as those performing the work.

    6 The Contractor shall furnish the Engineer with a signed inspection report for each item of
    work inspected and tested. The report shall indicate whether the item of work, material
    and/or equipment complies with all the inspection/test criteria. The Contractor shall submit
    inspection/test results to the Engineer prior to incorporating the item(s) into the work.
    Inspection/test failures shall be reported to the Engineer immediately.

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    7 Inspection and test reports shall, as a minimum, identify the following:

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    (a) inspection/test procedure reference
    (b) name of inspector/tester
    (c) observations/comments
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    (d) specified requirements
    (e) acceptability
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    (f) deviations/non-conformance
    (g) corrective action
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    (h) evaluation of results


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    (i) authorised signature


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    8 The Contractor shall clearly document and identify the inspections and test status of
    all materials and equipment throughout construction. Identification may be by means of
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    stamps, tags, or other control devices attached to, or accompanying, the material or
    equipment.
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    7.1.3 Inspection and Test Status


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    1 The inspection and test status of materials, equipment and construction work shall be
    identified by suitable means, which indicates the conformance or non-conformance of
    materials, equipment and construction work with regard to inspection and tests performed.
    The identification of inspection and test status shall be maintained, as defined in the Quality
    Assurance Plan and/or documented procedures, throughout the course of construction to
    ensure that only materials, equipment and construction work that have passed the required
    inspections and tests are used or installed.

    7.1.4 Inspections by the Engineer during construction

    1 The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and
    Record Review points for the Engineer during construction. The contractor shall prepare,
    document and implement a Request for Inspection system that defines how the Engineer will
    be given sufficient notice to inspect the works in accordance with the Inspection and Test
    Plans.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 07: Inspection and Test

    7.1.5 Inspections by the Engineer during Defects Liability Period

    1 The Engineer will give the Contractor due notice of his intention to carry out any inspections
    during the defects liability period.

    2 The Contractor shall arrange for a responsible representative to be present at the times and
    dates named by the Engineer.

    3 The Contractors representative shall render all necessary assistance and take note of all
    matters to which his attention is directed by the Engineer

    7.1.6 Workmanship

    1 The Contractor shall comply with industry standards except when more restrictive tolerances
    or specified requirements indicate more rigid standards or more precise workmanship.

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    2 Only persons qualified to produce workmanship of the required quality shall perform works

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    3 The Contractor shall comply with manufactures published installation instructions / guides in
    full, including each step in sequence. Should instructions conflict with project documentation,

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    the Contractor shall request clarification from the Engineer before proceeding.
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    7.1.7 Measuring and Test Equipment
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    1 The Contractor shall establish and maintain documented procedures which conform to
    accepted and approved national or international standards to control, calibrate and maintain
    inspection, measuring and test equipment used by the Contractor to demonstrate the
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    conformance of materials, equipment and/or construction work with the requirements of the
    Project Documentation.
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    2 Inspection, measuring and test equipment shall be used in a manner which ensures that the
    measurement uncertainty is known and is consistent with the required measurement
    capability
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    3 The Contractor shall establish a unique identification number for each item of measuring and
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    test equipment. This unique identification number shall be permanently affixed to each item
    of measuring and test equipment
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    4 The Contractor shall ensure that each item of inspection, measuring and test equipment is
    calibrated at intervals recommended by the manufacturer. Valid calibration certificates for
    measuring and testing equipment shall be present and available for inspection during
    inspections and tests.

    5 The Contractor shall establish a log of all measuring and test equipment and record:

    (a) equipment description


    (b) identification number
    (c) date of the last calibration
    (d) date that the next calibration is due.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 5
    Part 07: Inspection and Test

    6 The Contractor shall assess and record the validity of the previous measuring results when
    the equipment is subsequently found not to confirm to requirements. The Contractor shall
    take appropriate action on the equipment and any product affected.

    END OF PART

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 08: Materials

    8 MATERIALS .................................................................................................. 2
    8.1 GENERAL ...................................................................................................... 2
    8.1.1 Plant, Materials, Goods and Workmanship 2
    8.1.2 Handling and Storage of Materials 2
    8.1.3 Identification and Control of Items and Materials 2

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 08: Materials

    8 MATERIALS

    8.1 GENERAL

    8.1.1 Plant, Materials, Goods and Workmanship

    1 All Plant, materials, goods and workmanship shall be of the respective kinds described in the
    Contract with necessary approvals from the concerned authorities and in accordance with the
    Engineer's instructions and shall be subjected from time to time to such tests as the Engineer
    may direct at the place of manufacture or fabrication or on the Site or at all or any such
    places. The Contractor shall provide such assistance, instruments, machines, labour and
    material as are normally required for examining, measuring and testing any work and the
    quality, weight or quantity of any materials used and shall supply samples of materials before

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    incorporation in the Works for testing as may be selected and required by the Engineer.

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    8.1.2 Handling and Storage of Materials

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    1 The Contractor shall establish procedures for handling and storage of materials and
    equipment.

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    The Contractors storage and handling procedures shall be designed to prevent damage,
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    deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or
    substitution.
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    3 The handling procedures shall address the use, inspection and maintenance of special
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    devices such as crates, boxes, containers, dividers, slings, material handling and
    transportation equipment and other facilities.
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    4 The Contractor shall identify equipment and/or material requiring special handling or storage.
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    8.1.3 Identification and Control of Items and Materials


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    1 The Contractor shall establish control procedures to ensure that equipment and materials are
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    properly used and installed.


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    2 The Contractor shall identify all items and materials so that they are traceable throughout all
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    inspections, test activities, and records. For stored items, the identification method shall be
    consistent with the expected duration and type of storage.

    3 The Contractor shall record equipment and material identifications and ensure that they are
    traceable to the location where they are incorporated into the Works.

    END OF PART
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 1
    Part 09: Nonconformance Monitoring

    9 NONCONFORMANCE MONITORING .................................................................... 2


    9.1 INTRODUCTION ..................................................................................................... 2
    9.1.1 General 2
    9.1.2 Review and Disposition of Nonconforming Items 2
    9.1.3 Corrective Action 3
    9.1.4 Identification of Nonconforming Items 3
    9.1.5 Acceptance and Approval of Nonconforming items 4
    9.1.6 Nonconformance Records 4

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    QCS 2014 Section 02: Quality Assurance and Quality Control Page 2
    Part 09: Nonconformance Monitoring

    9 NONCONFORMANCE MONITORING

    9.1 INTRODUCTION

    9.1.1 General

    1 The Contractor shall ensure that product which does not conform to Specification
    requirements is identified and controlled to prevent its unintended use or delivery. A
    documented procedure shall be established to define the controls and relate responsibilities
    and authorities for dealing with nonconforming product:

    (a) by taking action to estimate the detected nonconformity


    (b) by authorizing its use, release or acceptance under concession by the Engineer

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    (c) by taking action to preclude its original intended use or application

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    (d) by taking action appropriate to the effects, or potential effects, of the nonconformity

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    when nonconformity product is detected after delivery or use has started .

    2 When Conforming product is corrected it shall be subject to re-verification to demonstrate


    conformity to requirements.
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    3 Records of the nature of nonconformities and any subsequent actions taken, including
    concessions obtained by the engineer, shall be maintained.
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    4 The monitoring system shall apply to material and equipment as well as installation and
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    construction which fail to conform to the Contract.


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    5 A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this


    Section and must be used for recording Nonconformance.
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    9.1.2 Review and Disposition of Nonconforming Items


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    1 The responsibility for review and authority for the disposition of nonconforming items shall be
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    defined in the Quality Plan.


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    2 Nonconforming items shall be reviewed in accordance with documented procedures. A


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    nonconforming item may be:

    (a) reworked to meet the specified requirements


    (b) accepted with or without repair if agreed in writing by the Engineer
    (c) re-graded for alternative applications
    (d) rejected or scrapped.

    3 The proposed use or repair of an item which does not conform to the requirements of the
    Project Documentation shall be reported to the Engineer. The description of the
    nonconformity and of repairs shall be recorded to denote the actual condition.

    4 Repaired and/or reworked products shall be inspected in accordance with the Quality
    Assurance Plan and/or documented procedures
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 3
    Part 09: Nonconformance Monitoring

    9.1.3 Corrective Action

    1 The Contractor shall take action to eliminate the causes of nonconformities in order to
    prevent recurrence. Corrective actions shall be appropriate to the effects of the
    nonconformity encountered.

    A documented procedure shall be established to define requirements for:

    (a) Reviewing nonconformities (including Engineer complaints)


    (b) Determining the causes of nonconformities
    (c) Evaluating the need for action to ensure that conformities do not occur
    (d) Determining and implementing actions needed
    (e) Records of the results of action taken and

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    (f) Reviewing the effectiveness of the corrective action taken

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    2 Any corrective or preventive action taken to eliminate the causes of actual or potential
    nonconformities shall be to a degree appropriate to the magnitude of problems and
    commensurate with the risks encountered.

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    The Contractor shall implement and record any changes to the documented procedures for
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    implementing corrective and preventive action.
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    4 The Contractor shall take prompt action to identify the causes of each nonconformance and
    the corrective action necessary prevent recurrence. The results of failure and discrepancy
    report summaries, Contractor evaluations, and any other pertinent applicable data shall be
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    used for determining corrective action. Information developed during construction, tests, and
    inspections that support the implementation of required improvements and corrections shall
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    be used to support the adequacy of corrective action taken.


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    5 The procedures for preventive action shall include:


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    (a) the use of appropriate sources of information such as processes and work operations
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    which affect product quality, concessions, audit results, quality records and service
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    reports to detect, analyse and eliminate potential causes of nonconformities


    (b) determination of the steps needed to deal with any problems requiring preventive
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    action
    (c) initiation of preventive action and application of controls to ensure that it is effective
    (d) ensuring that relevant information on actions taken is submitted for management
    review

    9.1.4 Identification of Nonconforming Items

    1 The Contractor shall clearly identify each nonconforming item with a status tag or other
    distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and
    removing these status tags and identify personnel authorised to remove status tags.
    QCS 2014 Section 02: Quality Assurance and Quality Control Page 4
    Part 09: Nonconformance Monitoring

    9.1.5 Acceptance and Approval of Nonconforming items

    1 Acceptance of the Contractors proposed disposition of Nonconforming items should be his


    obtained in writing from the Engineer prior to the undertaking of any remedial works by the
    his Contractor.

    2 Close out of Nonconforming items must be agreed in writing by the Engineer.

    9.1.6 Nonconformance Records

    1 The Contractor shall provide the Engineer with the following information for each
    nonconformance:

    (a) identification of nonconformance


    (b) description of nonconformance

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    (c) evaluation of nonconformance to establish the cause

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    (d) recommended corrective action
    (e) date nonconformance was identified
    (f) date corrective action was completed
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    (g) description of final corrective action.

    2 The Contractor shall establish and maintain a nonconformance log. The log shall contain the
    as

    following information as a minimum:


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    (a) unique sequential reference number


    (b) date issued
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    (c) originator
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    (d) description of item deemed to be in nonconformance


    (e) description of nonconformance
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    (f) Contractors recommended and final disposition


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    (g) Engineers acceptance of Contractors recommended and final disposition


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    (h) date closed


    (i) remarks, as applicable

    END OF PART
    QCS 2014 Section 03: Ground Investigation Page 1
    Part 01: General

    1 GENERAL ............................................................................................................... 2
    1.1 INTRODUCTION ..................................................................................................... 2
    1.1.1 Scope 2
    1.1.2 References 2
    1.1.3 Definitions 2
    1.2 SUBMITTALS .......................................................................................................... 3
    1.2.1 Programme of Works 3
    1.2.2 Preliminary Logs 3
    1.2.3 Exploratory Hole Logs 4
    1.2.4 Preliminary Laboratory Test Results 5
    1.2.5 Digital Data 5
    1.2.6 Form of Report 5

    .
    1.2.7 Approval of Report 6

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    1.3 QUALITY ASSURANCE .......................................................................................... 6

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    1.4 GENERAL PROJECT/SITE CONDITIONS .............................................................. 7
    1.4.1 General 7
    1.4.2
    1.4.3
    Working Areas
    Turf and Topsoil ta 7
    7
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    1.4.4 Paved Areas 7
    1.4.5 Paving Slabs and Blocks 7
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    1.4.6 Claims for Damage 8


    1.4.7 Geotechnical and Environmental Personnel 8
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    1.4.8 Location of Exploratory Holes 8


    1.4.9 Ground Elevation of Exploratory Holes 8
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    1.4.10 Exploratory Work 8


    1.4.11 Methods of Investigation 8
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    1.4.12 Safety and Management 9


    1.4.13 Anomalous Conditions 9
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    1.4.14 Surface Water Control 9


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    1.4.15 Photographs 9
    et

    1.4.16 Facilities for the Engineer 10


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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 01: General

    1 GENERAL

    1.1 INTRODUCTION

    1.1.1 Scope

    1 General requirements and information for the execution of ground investigations.

    2 Related Sections are as follows:

    Section 1 ......... General


    Section 2 ......... Quality Assurance and Quality Control
    Section 4 ......... Foundations and Retaining Structures
    Section 6 ......... Roadworks

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    Section 8 ......... Drainage Works

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    Section 12 ....... Earthworks Related to Buildings

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    1.1.2 References

    1 The following standards and other documents are referred to in this Part:

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    BS 5930......................Code of practice for site investigations
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    BS EN 1997................Ground Investigation and testing
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
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    Purposes
    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
    se

    Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US
    symposium on rock mechanics. AIME, New York, 1967
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    Code of Practice and Specifications for Road Openings in the Highway issued by the
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    Government.

    1.1.3 Definitions
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    1 Topsoil: the surface layer of earth that contains organic material and can also support
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    vegetation.
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    2 Soil: earthen material not classified herein as topsoil or hard stratum.

    3 Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean
    natural or artificial material, including rock, which cannot be penetrated except by the use of
    chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard
    stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below
    are fulfilled, provided that the boring rig involved is in good working order and is fully manned:

    (a) Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more
    than 300 mm

    (b) Condition (2) a standard penetration resistance test shows a resistance in excess
    of 35 blows/75 mm.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 01: General

    4 Fill: deposits or embankments which have been formed by persons, as distinct from
    geological agencies.

    5 Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the
    purpose of ground investigation.

    6 Boring: hole in earth, excavated by either percussion or auger equipment.

    7 Drilling: any hole in rock, excavated by rotary equipment.

    8 Borehole: exploratory hole excavated by boring or drilling techniques.

    1.2 SUBMITTALS

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    1.2.1 Programme of Works

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    1 The Geotechnical Investigation Contractor shall prepare a programme of works for the

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    investigation which will give a detailed schedule showing proposed time schedule for all
    aspect of the work, details of all plant and equipment to be used in addition to a list of
    personnel who will work on the project.
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    1.2.2 Preliminary Logs

    1 The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory
    as

    hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or
    trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer
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    in duplicate within seven working days of completion of the explorations to which they refer
    to, and shall contain the information required for the exploratory hole logs.
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    2 Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment
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    (MOE) requirements and/or those of other Government Departments, Ministries and


    Statutory Organizations.
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    3 The Geotechnical Investigation Contractor shall obtain all necessary work permits and
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    security permits prior to commencement of Geotechnical investigation of the site.


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    4 The investigation shall provide detailed information on the nature of the sub-strata, superficial
    deposits and ground water table at the site together with general recommendations for
    designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.

    5 The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in


    Section 2.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 01: General

    6 The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table


    1.1.
    Table 1.1: Minimum Depth of Boreholes

    No of floors Depth of Boreholes (m)

    3 or Less 6
    4 8
    5 9
    6 10
    7 12
    8 13
    0.7
    >8 3S

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    Notes:

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    The depth of boreholes is measured from foundation level.
    S is the number of floors.
    For structures small in plan area, exploration should be made at a minimum of three points,

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    unless other reliable information is available in the immediate vicinity. Where a structure
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    consists of a number of adjacent units, one exploration point per unit may suffice.
    For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the
    diameter of the pile at the toe) whichever is greater.
    as

    For roads, the depth of Boreholes shall be greater than 2m below the proposed formation
    Level.
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    For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:
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    2m below the inverted level;


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    1.5width of excavation.
    2D (D=Diameter or equivalent diameter of the tunnel/underground structure.
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    1.2.3 Exploratory Hole Logs


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    1 The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The
    logs shall include all the information that follows, such information having been updated as
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    necessary in the light of laboratory testing and further examination of samples and cores.

    2 Information for exploratory hole logs:

    Static
    Rotary Pit and and
    Drilling
    Borehole Trench Dynamic
    Probing

    All the designated information


    National grid co-ordinates
    Ground level related to the datum
    Elevation of each stratum referred to the datum ()
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 01: General

    Static
    Rotary Pit and and
    Drilling
    Borehole Trench Dynamic
    Probing
    Description of each stratum in accordance with BS
    5930 and initials of person who carried out the
    ()
    logging (and responsible Supervisor if under
    training)
    Details of groundwater observations ()
    Symbolic legend of strata in accordance with BS
    ()
    5930
    Core recovery as percentage of each core run
    Rock Quality Designation, RQD (Deere et al. 1967)
    _____

    .
    Note: means information required; () means information required if applicable.

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    1.2.4 Preliminary Laboratory Test Results

    1 Laboratory test results shall be submitted to the Engineer in batches at the completion of
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    each week's testing. Legible photocopies of work sheets are acceptable.
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    1.2.5 Digital Data
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    1 Data from the investigation shall be provided in digital form to the approval of the Engineer.
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    1.2.6 Form of Report


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    1 The report shall comprise of a factual or interpretative or both types of reports as required by
    the Employer or Engineer. Reports shall begin with a cover page showing the name of the
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    Contract and the names of the Employer, Engineer and Geotechnical Investigation
    Contractor. Report pages shall be numbered consecutively.
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    2 The factual report shall contain, as a minimum, the following information:


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    (a) A statement from the Engineer on the purpose and rationale of the investigation.
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    (b) A description of the work carried out, including reference to specification and
    standards adopted and any deviations from them.
    (c) Exploratory hole logs.
    (d) In-situ test records.
    (e) Laboratory test results.
    (f) Plan with locations of exploratory holes.
    (g) Site location plan.
    (h) Geological cross-sections (if appropriate).

    The plans shall be to a stated scale and shall include a north arrow. Additional information
    shall be provided as designated.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 01: General

    3 The interpretative report shall contain the following information:

    (a) A written appraisal of the ground and water conditions.


    (b) Analysis and recommendations as designated.

    When so designated, the Geotechnical Investigation Contractor shall supply the calculations
    and analyses on which recommendations are based.
    1.2.7 Approval of Report

    1 A draft copy of the factual report and the interpretative report shall be submitted to the
    Engineer for approval before submission of the final report.

    1.3 QUALITY ASSURANCE

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    1 Only Geotechnical Investigation Contractors holding a current approval certificate from the

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    Central Materials Laboratory shall be permitted to carry out ground investigations.

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    2 The work shall be carried out in accordance with the relevant British Standards or equivalent.

    3
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    Where specifically designated, all work shall be carried out in accordance with a quality
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    management system established in accordance with Section 2 Quality Assurance and Quality
    Control of the QCS. Records to indicate compliance with quality management shall be made
    available to the Engineer on request.
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    4 The Geotechnical Investigation Contractor shall provide full time professional attendance on
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    site. The professional attendant shall be approved by the Engineer, and shall be responsible
    for the technical direction of all fieldwork.
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    5 The Geotechnical Investigation Contractors geotechnical and environmental personnel


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    employed on the Contract shall be competent to undertake the work required. Categories of
    personnel who may be required by the Contract are as follows:
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    (a) Technician.
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    (b) Graduate Engineer/Geologist/Environmental Scientist.


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    (c) Graduate Engineer/Geologist/Environmental Scientist with at least three years of


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    relevant experience since graduation.


    (d) Professional Engineer/Geologist/Environmental Scientist with at least five years of
    relevant experience.
    (e) Professional Engineer/Geologist/Environmental Specialist with at least ten years of
    relevant experience.

    6 All drillers employed on the Contract shall be experienced and competent in percussion or
    auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent
    drilling supervisor per site shall be permanently on the Site during borehole operations.
    QCS 2014 Section 03: Ground Investigation Page 7
    Part 01: General

    1.4 GENERAL PROJECT/SITE CONDITIONS

    1.4.1 General

    1 Geotechnical Investigation Contractor shall only use access routes to and between
    exploration sites that are approved by the Engineer.

    2 Where the presence of underground services is likely, exploratory holes shall be started by
    means of a hand excavated inspection pit.

    3 In addition to any designated notice, at least one working day's notice of the intended time of
    entry shall be given to the land owner and occupier of the exploration site.

    4 All work shall be carried out with the least possible damage to the Site and its environs.

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    5 All barriers breached or otherwise disturbed during the execution of site operations shall be

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    immediately repaired or replaced to the same standard.

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    6 Working hours shall be restricted to those designated.

    7
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    Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the
    end of each days work.
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    1.4.2 Working Areas
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    1 Operations shall be confined to the minimum area of ground required for the Works. Unless
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    otherwise designated, on completion of each exploration all equipment, surplus material and
    rubbish of every kind shall be cleared away and removed from the Site. Damage to land or
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    property in the vicinity of the exploratory hole and on access routes shall be made good. The
    whole of the Site and any ancillary works shall be left in a clean and tidy condition.
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    1.4.3 Turf and Topsoil


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    1 Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future
    it

    replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by
    et

    the operations shall either be removed and stockpiled as above, or otherwise protected from
    damage. After completion of the exploration all topsoil shall be replaced and the Site
    m

    restored to its original condition.

    1.4.4 Paved Areas

    1 Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the
    minimum extent necessary for each exploration. After completion of the exploration and
    backfill of the excavation, the disturbed subgrade shall be compacted and the paving
    replaced.

    2 Restoration of highway pavement shall be in accordance with the current Code of Practice
    and Specification for Road Openings in the Highway issued by the Government.

    1.4.5 Paving Slabs and Blocks

    1 Paving slabs and blocks shall be removed from the Site, as required for each exploration,
    and stored for reuse.
    QCS 2014 Section 03: Ground Investigation Page 8
    Part 01: General

    2 Contiguous paving slabs and blocks which are liable to be damaged by the operations shall
    either be removed and stored as above or otherwise protected from damage.

    3 After completion of the exploration and backfill of the excavation, the disturbed subgrade
    shall be compacted and the paving slabs and blocks relayed.

    1.4.6 Claims for Damage

    1 Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall
    be reported to the Engineer.

    1.4.7 Geotechnical and Environmental Personnel

    1 In addition to the provision of the designated personnel by the Geotechnical Investigation


    Contractor, the Engineer may specifically require the services of geotechnical and

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    environmental personnel for advice, assistance or preparation of interpretative reports. The

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    form of interpretative reports shall be agreed with the Engineer. Details of the qualifications

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    and experience of the personnel shall be supplied to the Engineer.

    1.4.8 Location of Exploratory Holes

    1 ta
    The location of each exploratory hole shall be measured from an approved grid co-ordinate
    qa
    system, and shall be accurate to within 1 m, and the position recorded on a plan as
    designated.
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    1.4.9 Ground Elevation of Exploratory Holes


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    1 The elevation of the ground at each exploratory hole shall be established, on the basis of the
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    Qatar National Datum unless otherwise designated or approved by the Engineer, to the
    nearest 0.05 m.
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    1.4.10 Exploratory Work


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    1 The location and depth of each exploratory hole shall be as designated. The Engineer may,
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    after consultation with the Geotechnical Investigation Contractor, vary the location and depth
    of any exploratory hole and the sequence or quantity of in-situ testing depending on the
    m

    actual ground conditions encountered. When the position of an exploratory hole has been
    varied, the Geotechnical Investigation Contractor shall take all necessary measurements and
    shall inform the Engineer of the revised co-ordinates and ground elevation or other
    measurements required to locate the exploratory hole.

    1.4.11 Methods of Investigation

    1 The Engineer will have the option to require any of the following methods of investigation.
    These options will comprise, but not necessarily be limited to, the following:

    (a) Desk study.


    (b) Geological mapping.
    (c) Topographic survey.
    (d) Aerial photographs.
    or any other methods described in this Section.
    QCS 2014 Section 03: Ground Investigation Page 9
    Part 01: General

    1.4.12 Safety and Management

    1 The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA)
    to all site activities including but not limited to potential hazard, who/what might be harmed,
    control/ recovery measure, responsible personetc.

    2 The presence and nature of known areas of hazardous or contaminated ground are
    designated, based on available records. If evidence of further hazardous or contaminated
    ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform
    the Engineer. If required by the Engineer, the Geotechnical Investigation Contractors work
    plan shall be revised appropriately to take into account the nature and level of contamination
    encountered. Where contaminated land is present or suspected the Geotechnical
    Investigation Contractor shall take the appropriate health and safety precautions as directed
    by the Engineer and where appropriate by the Civil Defence Department of the Government.
    Care shall be taken to avoid contaminating the egress from the Site.

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    3 A method statement indicating the safety procedures to be followed during the investigation

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    of hazardous or contaminated ground shall be provided by the Geotechnical Investigation
    Contractor before beginning the investigation in the hazardous or contaminated ground.

    4
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    Traffic safety and management measures shall be provided, in accordance with the
    qa
    provisions of traffic control of Section 1, General. Where the circumstances of any particular
    case are not designated, proposals for dealing with such situations shall be submitted to the
    Engineer for approval.
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    1.4.13 Anomalous Conditions


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    1 Where anomalous or unexpected features are revealed, the Geotechnical Investigation


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    Contractor shall immediately inform the Engineer.


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    1.4.14 Surface Water Control

    1 Surface water or other water shall be prevented from entering the exploratory hole, except as
    o

    permitted by the Engineer.


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    1.4.15 Photographs
    m

    1 Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor
    as designated. Each photograph shall clearly show all necessary details, and shall have its
    scale identified.

    2 A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be
    submitted to the Engineer for his approval, within seven working days of the photography. In
    the event that the photographs are of a quality unacceptable to the Engineer, they shall be
    retaken.

    3 On acceptance of the quality of the photograph, two complete sets of prints of all the
    photographs shall be presented, annotated and submitted in bound volumes, together with
    the original photograph digital format with the factual report.

    4 Particular requirements for photographs of cores and pits and trenches are given in Parts 3
    and 4
    QCS 2014 Section 03: Ground Investigation Page 10
    Part 01: General

    1.4.16 Facilities for the Engineer

    1 When required by the particular contract documentation, facilities to the designated standard
    shall be provided for the use of the Engineer, as described in Section 1.

    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 02: Boreholes

    2 BOREHOLES .......................................................................................................... 2
    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.1.2 References 2
    2.2 BOREHOLES GENERALLY .................................................................................... 2
    2.2.1 Method and Diameter 2
    2.2.2 Addition of Water to the Borehole 3
    2.2.3 Backfilling 3
    2.3 PERCUSSION BORING .......................................................................................... 3
    2.3.1 Hard Stratum or Obstruction in Percussion Boring 3
    2.4 AUGER BORING ..................................................................................................... 3
    2.4.1 Hand Auger 3

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    2.4.2 Continuous Flight Auger Boring 3

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    2.4.3 Hollow Stem Flight Auger 3

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    2.5 ROTARY DRILLING ................................................................................................ 3
    2.5.1 General 3
    2.5.2
    2.5.3
    Drilling Fluid
    Rotary Drilling with Core Recovery ta 4
    4
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    2.5.4 Rotary Drilling without Core Recovery 6
    2.5.5 Backfilling 6
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    2.5.6 Photographs 6
    2.6 BOREHOLES OVERWATER .................................................................................. 6
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 02: Boreholes

    2 BOREHOLES

    2.1 GENERAL

    2.1.1 Scope

    1 Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 ............... General

    Section 4, ........ Foundations and Retaining Structures

    .
    Section 6, ........ Roadworks

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    Section 8, ........ Drainage Works
    Section 12, ...... Earthworks Related to Buildings

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    2.1.2 References

    1
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    The following standards and other documents are referred to in this Part:
    qa
    BS 5930 ......................Code of practice for site investigations.
    BS EN 1997 ................Ground Investigation and testing
    as

    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction


    Purposes
    se

    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


    Engineering Group of the Geological Society Working Party Report The logging of rock cores
    er

    for engineering purposes (1970).


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    2.2 BOREHOLES GENERALLY


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    2.2.1 Method and Diameter


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    et

    1 The method of advancement and the diameter of a borehole shall be such that the boring
    m

    can be completed and logged to the designated depth, and samples of the designated
    diameter can be obtained, in-situ testing carried out and instrumentation installed.

    2 The following methods may be employed for advancement of a borehole unless otherwise
    designated:

    (a) Percussion boring.


    (b) Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the
    Employer that the SPT values obtained are not effected by disturbance of the soil by
    the auger head, or the presence of material within the hollow stem.).
    (c) Rotary drilling.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 02: Boreholes

    2.2.2 Addition of Water to the Borehole

    1 Jetting with water shall not be used to assist the advance of the borehole, except where
    approved by the Engineer. Where the borehole penetrates below the water table and
    disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.

    2.2.3 Backfilling

    1 The Contractor shall backfill boreholes in such a manner as to minimise subsequent


    depression at the ground surface due to settlement of the backfill. In some circumstances,
    grout or special infilling may be required by the Engineer. Where artesian or other water
    conditions make normal backfilling impracticable, the Contractor shall consult and agree with
    the Engineer a procedure for sealing the borehole.

    2.3 PERCUSSION BORING

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    2.3.1 Hard Stratum or Obstruction in Percussion Boring

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    1 In a borehole where percussion boring is employed and a hard stratum or obstruction is
    encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.
    ta
    Should this not penetrate through the hard stratum or obstruction the Contractor shall inform
    qa
    the Engineer, who may instruct the use of one or more of the following:

    (a) continuation of chiselling techniques


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    (b) rotary or other approved drilling until the stratum is penetrated


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    (c) abandonment of the borehole.


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    2.4 AUGER BORING


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    2.4.1 Hand Auger

    1 Hand auger boring may be appropriate in suitable self-supporting strata.


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    2.4.2 Continuous Flight Auger Boring


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    1 Where continuous flight auger boring is used, it shall be carried out under the full-time
    supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c)
    who shall produce, as boring proceeds, a record of the material and groundwater
    encountered.

    2.4.3 Hollow Stem Flight Auger

    1 Where hollow stem flight auger boring is used, the equipment used shall be such as to bore
    and recover samples as designated. Sampling shall be carried out through the hollow stem.

    2.5 ROTARY DRILLING

    2.5.1 General

    1 Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in
    rock, with or without core recovery.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 02: Boreholes

    2.5.2 Drilling Fluid

    1 The drilling fluid shall normally be clean water, air or air mist. However, with the approval of
    the Engineer, drilling muds, additives or foam may be used.

    2.5.3 Rotary Drilling with Core Recovery

    1 Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube
    coring system incorporating a removable inner liner or split tube. The triple tube system may
    be affected by use of a double tube barrel with an approved semi-rigid liner.

    2 Rotary core drilling shall produce cores of not less than the designated diameter throughout
    the core length. Care shall be exercised in the drilling so as to optimise core recovery.

    3 The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not

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    normally exceed 3 m in length and the core barrel shall be removed from the drill hole as
    often as is required to obtain the best possible core recovery or alternatively the core

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    samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing
    between drill runs.

    4 ta
    Removal of cores and labelling of liners shall be carried out as follows:
    qa
    (a) All operations entailed in recovering the cores from the ground after completion of
    drilling shall be carried out in a manner such as to minimise disturbance to the cores.
    as

    (b) Core barrels or inner tube in case of wireline shall be held horizontally while the
    innermost liner containing the core is removed without vibration and in a manner to
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    prevent disturbance to the core. The core should be rigidly supported at all times while
    it is being extruded and during subsequent handling, and the liner containing the core
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    must not be allowed to flex


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    (c) Immediately after removing the liner the top and bottom shall be marked in indelible
    ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall
    o

    be cut to the length of the enclosed core. Alternatively, should a metallic split tube be
    it

    used, the samples shall be placed in half cut PVC pipes sealed with the second half
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    after core samples description with marking of the core run on the PVC tube and the
    core box.
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    (d) Where the length of core recovered from any single core run is such that it cannot be
    accommodated in one channel of the core box, the liner shall be cut to coincide, if
    possible, with existing fractures. The liner either side of the cut shall be marked 'cut'
    and the ends capped as above.
    (e) Each section of liner shall be marked with the contract title, exploratory hole reference
    number, date and the depths of the top and bottom of the drill run.
    (f) Core obtained without a liner and that from within the core catcher but not inside the
    liner shall be wrapped in two layers of plastic cling film and labelled to indicate the
    depth and exploratory hole reference number.

    5 Core boxes, packing, labelling, storing shall be carried out as follows:

    (a) Core boxes shall be soundly constructed and fitted with stout carrying handles,
    fastenings and hinged lids. The total weight of the cores and box shall together not
    exceed 60 kg.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 02: Boreholes

    (b) Cores shall be rigidly and securely packed at the site of drilling and during all
    subsequent handling and storage the cores shall remain packed unless required for
    examination or testing. Cores shall be placed in the box, in their liners where used,
    with the shallowest core to the top left hand corner, the top being considered adjacent
    to the hinged section. Cores from the core catcher shall also be placed in the core
    boxes at the correct relative depth.
    (c) Depth shall be indicated on the core box by durable markers at the beginning and end
    of each drill run. Rigid core spacers shall be used to indicate missing lengths. The
    contract title, exploratory hole reference number and the depth of coring contained in
    each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand
    end of the box and on the inside of the box lid.
    (d) Core boxes containing core shall be kept horizontal and moved and handled with care
    at all times. Cores shall be protected from direct sunlight. At the end of each day's
    work, core boxes shall be stored secure from interference and protected from the

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    weather.

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    6 Cores shall be prepared for examination as follows:

    (a) Cores shall be prepared for examination by the removal of sealing materials and

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    splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut
    lengthways such that at least half the core circumference is exposed. If half PVC is
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    used, care should be taken while removing and replacing the split half.
    (b) Before examination of the core, the Contractor shall photograph the cores. The time
    as

    between beginning preparation and the examination of the prepared and photographed
    cores shall be minimised to prevent loss of moisture from the core samples.
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    (c) Cores shall be examined and described on site by a person meeting the requirements
    of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D
    er

    2488 and the recommendations of the Engineering Group of the Geological Society
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    Working Party Report The logging of rock cores for engineering purpose (1970).

    7 When the examination of the cores has been completed, the Contractor may be required to
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    retain separately designated core sub-samples for possible laboratory testing. The Contractor
    it

    shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of
    et

    moisture and sample disturbance. They shall be clearly labelled so that the location, depth
    and origin of the sub-samples can be readily identified. Cores in their liners remaining after
    m

    the designated sub-samples have been removed shall be end-capped and resealed and
    replaced in the original core box location. Rigid spacers shall be placed in the spaces in the
    cores boxes previously occupied by the core sub-samples to prevent movement of adjacent
    cores and these shall be labelled identically to the core sub-samples that they replace. The
    core sub-samples shall be retained in separate core boxes clearly marked to indicate the
    origin of the cores contained within.

    8 The Contractor shall protect all cores and transport them including loading and unloading to

    (a) The Contractor's premises.


    (b) For a number of selected cores, to the designated address.

    9 After submittal of the approved final report, the Contractor shall retain cores, other than those
    delivered to the designated address, for a period of time required by the Engineer. The
    Engineer's written permission shall be obtained before disposal of the cores, but the required
    retention period will normally not exceed three months.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 02: Boreholes

    2.5.4 Rotary Drilling without Core Recovery

    1 Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole
    diameter shall be as designated.

    2 When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other
    cavities or anomalous conditions, drilling shall be under the full-time supervision of a person
    meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a
    systematic record shall be made of the drilling methods, rate of penetration, loss of flushing
    medium, the material penetrated and any cavities or broken ground encountered.

    2.5.5 Backfilling

    1 Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean,

    .
    well graded aggregate. The aggregate size and gradation shall be approved by the Engineer.

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    Under special circumstances grout may be required to backfill the holes. The grout shall
    consist of equal portions by weight of ordinary Portland cement and bentonite mixed by

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    machine or hand to a uniform colour and consistency before placing, with a moisture content
    not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of

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    a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds.
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    2 Where artesian water conditions or voids make normal grouting impracticable, the Contractor
    shall consult and agree with the Engineer a procedure for sealing the drill hole.
    as

    2.5.6 Photographs
    se

    1 In addition to the requirements of Part 1, the Contractor shall photograph cores where
    required in a fresh condition before logging and ensure that the following criteria are fulfilled:
    er

    (a) A graduated scale in centimetres is provided.


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    (b) Labels and markers are clearly legible in the photograph.


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    (c) A clearly legible reference board identifying the project title, exploratory hole number,
    date, and depth of drill runs shall be included in each photograph.
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    (d) Core boxes are evenly and consistently lit.


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    (e) The length of the core box in each photograph fills the frame.
    (f) The focal plane of the camera and the plane of the core box are parallel.
    (g) The camera is placed in the same position with respect to the core box in every
    photograph.
    (h) The resolution of the camera is not less than 8Mpixels.
    (i) The photograph taken should be in focus along all the core samples length.

    2.6 BOREHOLES OVERWATER

    1 When boreholes are required overwater the method of drilling and sampling shall comply in
    general with the other requirements given in this Section, with the exception of backfilling.

    2 Overwater boreholes shall be undertaken by the use of overwater staging, work over platform
    (WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the
    Engineer.
    QCS 2014 Section 03: Ground Investigation Page 7
    Part 02: Boreholes

    3 Control of the elevation related to the borehole/seabed surface or varying stratums shall be
    related to the top of the casing installed. Anchored floating vessels will keep a constant
    record of tidal movement between the vessel and the fixed casing elevation and make any
    allowances necessary.

    4 Boring or drilling operations will cease when the wave height exceeds the designated
    maximum value relating to standing time due to inclement weather, if this item is applicable
    to the Contract under the contract specific documentation.

    5 An accurate method of measuring wave height from trough to crest will be installed on the
    drilling vessel or platform and calibrated and approved by the Engineer before beginning
    drilling operations.

    6 All overwater operations will comply with all local government regulations related to such
    work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at

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    the time.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 03: Pits and Trenches

    3 PITS AND TRENCHES ........................................................................................... 2


    3.1 GENERAL ............................................................................................................... 2
    3.1.1 Scope 2
    3.1.2 References 2
    3.1.3 Quality Assurance 2
    3.2 PITS AND TRENCHES GENERALLY ..................................................................... 2
    3.2.1 Pit and Trench Dimensions 2
    3.2.2 Contaminated Ground 2
    3.2.3 Groundwater 3
    3.2.4 Protection to Pits and Trenches Left Open 3
    3.2.5 Backfilling and Restoration 3
    3.2.6 Photographs 3

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    3.3 INSPECTION PITS .................................................................................................. 3

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    3.3.1 Excavation Method 3

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    3.3.2 Services 3
    3.3.3 Sidewall Stability 4
    3.4
    3.4.1 Excavation Method ta
    TRIAL PITS AND TRENCHES ................................................................................ 4
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    3.4.2 Services 4
    3.4.3 Sidewall Stability 4
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    3.4.4 Trial Pits Examination 4


    3.5 OBSERVATION PITS AND TRENCHES ................................................................. 4
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    3.5.1 Excavation Method 4


    3.5.2 Services 5
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    3.5.3 Sidewall Stability 5


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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 03: Pits and Trenches

    3 PITS AND TRENCHES

    3.1 GENERAL

    3.1.1 Scope

    1 Inspection pits, trial pits and trenches, observation pits and trenches.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General

    Section 1, ....... General

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    Section 4, ....... Foundations and Retaining Structures

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    Section 6, ....... Roadworks
    Section 8, ....... Drainage Works

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    Section 12, ..... Earthworks Related to Buildings.

    3.1.2 References

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    1 The following standards and other documents are referred to in this Part:
    BS 5930 ...................... Code of practice for site investigations
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    BS EN 1997 ................Ground Investigation and testing


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    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction


    Purposes
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    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


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    Code of Practice and Specifications for Road Openings in the Highway issued by the
    Government.
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    3.1.3 Quality Assurance


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    1 Trial pits and trenches and observation pits and trenches shall be examined and described
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    by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item
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    (c) and photographed, if required.

    3.2 PITS AND TRENCHES GENERALLY

    3.2.1 Pit and Trench Dimensions

    1 Unless otherwise designated


    2.
    (a) Trial pits and observation pits shall have a minimum base area of 1.5 m
    (b) Trial trenches and observation trenches shall not be less than 1 m wide.

    3.2.2 Contaminated Ground

    1 Ground that is suspected of being contaminated shall be described by an environmental or


    geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5
    Paragraph 5 Item (c).
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 03: Pits and Trenches

    3.2.3 Groundwater

    1 The Contractor shall divert surface water runoff from entering pits and trenches.

    2 Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous
    work if required.

    3.2.4 Protection to Pits and Trenches Left Open

    1 Where pits and trenches are required to be left open and unattended, the Contractor shall
    provide fencing together with all necessary lighting and signing.

    2 Precautions shall be taken to protect the pits and trenches from the adverse effects of
    weather during this period.

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    3.2.5 Backfilling and Restoration

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    1 Pits and trenches shall be backfilled as soon as practicable and reinstated to their original
    condition.

    2
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    The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as
    to minimise any subsequent settlement of the ground surface.
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    3 The use of sand backfill compacted by flooding may be permitted, but this method requires
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    the approval of the Engineer.

    4 In paved areas, the pavement shall be restored.


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    3.2.6 Photographs
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    1 In addition to the requirements of Part 1, photographs shall clearly show details of the ground
    ov

    conditions in the pit and trench with any support in place and shall contain a graduated scale.
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    2 Material derived from the excavation shall be photographed, when directed by the Engineer.
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    Artificial lighting shall be used where necessary.


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    3 Unless directed otherwise by the Engineer, three photographs will normally be required at
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    every pit and trench.

    3.3 INSPECTION PITS

    3.3.1 Excavation Method

    1 Inspection pits for the location of underground services shall be excavated by hand to a
    depth of 1.2 m unless otherwise designated.

    2 Hand-operated power tools may be used to assist excavation where necessary.

    3.3.2 Services

    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 03: Pits and Trenches

    3.3.3 Sidewall Stability

    1 Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

    3.4 TRIAL PITS AND TRENCHES

    3.4.1 Excavation Method

    1 Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by
    machine to the required depth to enable visual examination and sampling from outside the pit
    or trench as required.

    2 Where dewatering is required, the pumping equipment used shall be adequate to lower the
    water table to the required level.

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    3.4.2 Services

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    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.

    3.4.3 Sidewall Stability


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    1 Excavations deeper than 1.2 m shall be braced if necessary.
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    3.4.4 Trial Pits Examination


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    1 All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or
    ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society
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    Working Party.
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    2 Disturbed samples shall be obtained from the trial pits for laboratory testing and geological
    description purposes. The samples shall be taken to be representative of the actual site
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    conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories
    for examination and testing.
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    3 Color photographs shall be taken for each excavated trial pit with a metric scale laid into the
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    pit after cleaning it, indicating the pits details such as trial pit number, date and depth.

    3.5 OBSERVATION PITS AND TRENCHES

    3.5.1 Excavation Method

    1 Observation pits and trenches shall be excavated by hand or machine and shall be
    adequately supported to enable personnel to enter safely and to permit in-situ examination,
    soil sampling and testing as required. In areas where dewatering is required, the equipment
    and methods proposed must be approved by the Engineer before beginning the work.

    2 All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or
    ASTM D 2488.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 03: Pits and Trenches

    3 Disturbed samples shall be obtained for laboratory testing and geological description
    purposes (if required). The samples shall be taken to be representative of the actual site
    conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories
    for examination and testing.

    4 Color photographs shall be taken for each excavated pit with a metric scale laid into the pit
    after cleaning it, indicating the pits details such as trial pit number, date and depth.

    3.5.2 Services

    1 The locations, depths and dimensions of all services encountered shall be measured and
    recorded in the daily report with other designated information.

    3.5.3 Sidewall Stability

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    1 Due care shall be exercised to ensure the stability of the sides of the excavation at all times.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 04: Soil Sampling

    4 SOIL SAMPLING ..................................................................................................... 2


    4.1 GENERAL ............................................................................................................... 2
    4.1.1 Scope 2
    4.1.2 References 2
    4.2 SAMPLING GENERALLY ........................................................................................ 2
    4.2.1 Sampling and Testing Frequency 2
    4.2.2 Recording depths of samples 3
    4.2.3 Description of samples 3
    4.2.4 Labelling, Protection and Transportation of Samples 3
    4.2.5 Retention and Disposal of Samples 3
    4.3 SOIL SAMPLES....................................................................................................... 3
    4.3.1 Small Disturbed Samples 3

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    4.3.2 Bulk Disturbed Samples 3

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    4.3.3 Open Tube and Piston Samples 4

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    4.3.4 Standard Penetration Test Samples 4
    4.4 GROUNDWATER SAMPLES .................................................................................. 4
    4.5 SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND
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    LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4
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    4.6 GAS SAMPLING...................................................................................................... 5
    4.7 SPECIAL SAMPLING .............................................................................................. 5
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 04: Soil Sampling

    4 SOIL SAMPLING

    4.1 GENERAL

    4.1.1 Scope

    1 Taking of samples of soil, groundwater, gas and contaminants. Sample handling,


    transportation, storage, retention and disposal.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General
    Part 2, .............. Boreholes

    .
    Part 3, .............. Pits and Trenches.

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    4.1.2 References

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    1 The following documents are referred to in this Part:

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    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
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    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
    as

    BS 5930 ......................Code of practice for site investigations


    BSI DD 175 ..............Code of practice for the identification of potentially contaminated land
    se

    and its investigation (draft for development).


    BS EN 1997--- ............ Ground Investigation and testing
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    ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in
    construction, Part 4, Guidelines for the safe investigation by drilling of landfills and
    contaminated land, Thomas Telford, (1993).
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    et

    4.2 SAMPLING GENERALLY


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    4.2.1 Sampling and Testing Frequency

    1 The frequency of sampling and in-situ testing is dependent on the ground conditions. In the
    absence of designated requirements the intervals observed shall be as follows:

    (a) in boreholes
    (i) first open tube sample (generally in clay soils) or standard penetration test
    (SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth,
    thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.

    (ii) small disturbed samples shall be taken from the topsoil, at each change in soil
    (iii) type or consistency and midway between successive open tube samples or
    SPTs.
    (iv) Bulk disturbed samples shall be taken of each soil type.
    (b) in pits and trenches
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 04: Soil Sampling

    (i) Small disturbed samples shall be taken of the topsoil, at each change in soil
    type or consistency and between successive bulk disturbed samples.
    (ii) Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one
    large bulk disturbed sample of each soil type.

    4.2.2 Recording depths of samples

    1 The depths below ground level at which samples are taken shall be recorded. For open tube
    and piston samples the depth to the top and bottom of the sample, and the length of sample
    obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.

    4.2.3 Description of samples

    1 All samples shall be examined and described by a geotechnical person meeting the

    .
    requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930.

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    Samples of suspected contaminated ground and leachate shall be described by an
    environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5,

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    Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell
    with reference to specific inclusions.

    4.2.4 Labelling, Protection and Transportation of Samplesta


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    1 Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater,
    leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a
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    red label.
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    2 Samples shall be protected from direct heat and sunlight.


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    3 Samples shall be transported to the Contractor's premises. Where required by the Engineer,
    selected samples shall be delivered to the designated address.
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    4.2.5 Retention and Disposal of Samples


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    1 Samples shall be kept for the designated period after submission of the approved final report.
    et

    This period shall not exceed three months, unless specifically designated otherwise. The
    Contractor shall ultimately dispose of all samples other than those delivered to the
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    designated address.

    4.3 SOIL SAMPLES

    4.3.1 Small Disturbed Samples

    1 Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately
    in airtight containers, which they should sensibly fill.

    4.3.2 Bulk Disturbed Samples

    1 Bulk disturbed samples shall be representative of the zone from which they have been taken.

    2 Normal bulk disturbed samples shall weigh not less than 10 kg.

    3 Large bulk disturbed samples shall weigh not less than 30 kg.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 04: Soil Sampling

    4.3.3 Open Tube and Piston Samples

    1 Open tube and piston samples shall be taken using the sampling equipment and procedures
    as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.

    2 Before an open tube or piston sample is taken, the bottom of the hole shall be carefully
    cleared of disturb materials and where a casing is being used the sample shall be taken
    below the bottom of the casing. Following a break in the work exceeding one hour, the
    borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.

    3 Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be
    cleaned out for the full depth to which the sampling tube has penetrated and the recovered
    soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of
    the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful

    .
    the Contractor shall agree with the Engineer as to alternative means of sampling.

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    4 The samples shall be sealed immediately to preserve their natural moisture content and in

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    such a manner as to prevent the sealant from entering any voids in the sample.

    5 Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed
    sample.
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    4.3.4 Standard Penetration Test Samples
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    1 When a standard penetration test (SPT) is made, the sample from the split barrel sampler
    shall be retained as a small disturbed sample.
    se

    4.4 GROUNDWATER SAMPLES


    er

    1 Groundwater samples shall be taken from each exploratory hole where groundwater is
    ov

    encountered. Where more than one groundwater level is found, each one shall be sampled
    separately. Where water has been previously added, the hole shall be bailed out before
    o

    sampling so that only groundwater is present. The sample volume shall be not less than 0.25
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    4.5 SAMPLES OF SUSPECTED CONTAMINATED GROUND,


    m

    GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS

    1 Samples of suspected contaminated ground, groundwater and leachate shall be taken in


    accordance with DD 175 and the SISG publication under the supervision of an environmental
    or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).

    2 The size and type of sample and container, method of sampling and time limitations for
    carrying out specific analyses shall be commensurate with the range of analyses to be
    carried out or as designated.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 04: Soil Sampling

    4.6 GAS SAMPLING

    1 Samples of gas for chromatographic analysis shall be obtained from exploratory holes or
    standpipes in accordance with DD 175 and the SISG publication. The sampling method shall
    relate to the volume of gas available and the type of laboratory analysis. The sampler
    receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas
    bombs.

    4.7 SPECIAL SAMPLING

    1 The Engineer may require special sampling. This work will normally require supervision on
    site by a geotechnical person and shall be carried out in accordance with BS 5930 or as
    designated.

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    END OF PART

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    QCS 2014 Section 03: Ground Investigation Page 1
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5 IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2


    5.1 GENERAL ............................................................................................................... 2
    5.1.1 Scope 2
    5.1.2 References 2
    5.2 TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2
    5.2.1 Testing 2
    5.2.2 Instrumentation and Monitoring 3
    5.3 TESTS ..................................................................................................................... 3
    5.3.1 Tests in accordance with BS 1377 or BS EN 1997 3
    5.3.2 Tests in accordance with BS 5930 4
    5.3.3 Geophysical Methods of Investigation 4
    5.3.4 Special In-Situ Testing 4

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    5.3.5 Hand Penetrometer and Hand Vane for Shear Strength 5

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    5.3.6 Self-boring Pressuremeter 5

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    5.4 INSTRUMENTATION AND MONITORING .............................................................. 6
    5.4.1 Groundwater 6
    5.4.2
    5.4.3
    Installation of Standpipes and Piezometers
    Installation of Gas Monitoring Standpipes ta 6
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5 IN-SITU TESTING, INSTRUMENTATION AND MONITORING

    5.1 GENERAL

    5.1.1 Scope

    1 Testing of soils in place, and provision of instrumentation and monitoring of groundwater and
    subsurface gases.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 ............... General
    Part 2 ............... Boreholes

    .
    Part 3 ............... Pits and Trenches.

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    5.1.2 References

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    1 The following standards and other documents are referred to in this Part:

    ta
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
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    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
    BS 1377......................Methods of tests for soils for civil engineering purposes
    as

    BS 5930......................Code of practice for site investigations


    BS 7022......................Geophysical logging of boreholes for hydrogeological purposes
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    BS EN 1997................Ground Investigation and testing


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    The Geological Society Engineering Group Working Party Report on Engineering


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    Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.


    Clarke B.G. and Smith A., A model specification for radial displacement measuring
    o

    pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.


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    et

    5.2 TESTING, INSTRUMENTATION AND MONITORING GENERALLY


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    5.2.1 Testing

    1 The following information shall be submitted for each test record to be included in the daily
    report, preliminary log and factual report:

    (a) Date of test.


    (b) Project name, exploratory hole number and location.
    (c) Depth and location of test or depths covered by test.
    (d) Information on water levels in exploratory hole during testing.
    (e) Original ground level at test site.
    (f) Soil type and description as identified from the sample.

    2 All results shall be reported in SI units.


    QCS 2014 Section 03: Ground Investigation Page 3
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    3 Where load, displacement or other measuring equipment is used which necessitates regular
    calibration, then this shall be carried out in accordance with the relevant standard (the
    preferred method) or the manufacturer's instructions, by a calibration service approved by the
    Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall
    be supplied to the Engineer prior to commencing work and when otherwise requested.

    5.2.2 Instrumentation and Monitoring

    1 The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected
    by a cover. The type of protective cover shall be approved by the Engineer.

    2 When instructed by the Engineer, the Contractor shall install a protective fence around the
    top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle
    iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the
    climate of Qatar or a fence as a agreed upon with the Engineer.

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    3 Daily readings of depths to water in groundwater monitoring standpipes and piezometers

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    shall be made by the Contractor, with an instrument approved by the Engineer.

    4 Where the presence of gas is suspected or when directed by the Engineer, gas

    ta
    measurements, using an approved in-situ meter, shall be made by the Contractor during
    construction of exploratory holes and in gas monitoring standpipes. The depth to water and
    qa
    barometric pressure shall be measured immediately after each gas measurement.
    as

    5 Unless otherwise designated, piezometers, and standpipes protection shall not be removed
    from the site.
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    6 Other instrumentation and monitoring shall be carried out as designated.


    er

    5.3 TESTS
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    5.3.1 Tests in accordance with BS 1377 or BS EN 1997


    o

    1 The following in-situ tests shall be carried out and reported in accordance with BS 1377 or
    it

    BS EN 1997:
    et

    (a) in-situ density by


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    (i) Small pouring cylinder method.


    (ii) Large pouring cylinder method.
    (iii) Water replacement method.
    (iv) Core cutter method.
    (v) Nuclear method.
    (b) Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise
    designated
    (c) Dynamic probing (DPH or DPSH).
    (d) Standard penetration test (SPT).
    (e) Plate loading test.
    (f) Shallow pad maintained load test.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    (g) California bearing ratio (CBR).


    (h) Vane shear strength.
    (i) Apparent resistivity of soil.
    (j) Redox potential.
    (k) Pressurementer or Self-boring Pressuremeter (PMT)
    (l) Pocket Penetrometer.

    5.3.2 Tests in accordance with BS 5930

    1 The following in-situ tests shall be carried out where applicable and reported in accordance
    with BS 5930:
    (a) Constant head permeability test.

    .
    (b) Variable head permeability test.

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    (c) Packer permeability test.

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    5.3.3 Geophysical Methods of Investigation

    1 Geophysical testing shall be carried out as designated. The Contractor shall submit to the

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    Engineer a full description of equipment and procedure for each geophysical method
    qa
    required.

    2 The equipment and procedure, and information to be submitted for the following geophysical
    as

    methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological


    Society Engineering Group Working Party Report on Engineering Geophysics:
    se

    3
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    (a) electrical resistivity method


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    (b) seismic refraction and reflection method


    (c) magnetic method
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    (d) gravity method


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    (e) electromagnetic method


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    (i) Ground conductivity.


    (ii) Transient electromagnetic.
    (iii) Ground probing radar (optional).
    (f) Borehole geophysical logging.
    (g) Cross-hole seismic method.
    (h) Multi Channel Analysis of Surface Waves (MASW)
    (i) Refraction Microtremor (ReMi)

    5.3.4 Special In-Situ Testing

    1 Special in-situ testing shall be carried out as designated.

    2 The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for
    the execution of inspection tests.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    3 Inspection tests shall be decided as directed by the Engineer. These tests shall include but
    not limited to those in Table 3.2.

    Table 3.2: Quality Assurance Tests for Completed Work

    Recommended Test per Layer

    Shallow Fill Deep Fill


    (trench or test pit) (boreholes)
    In-situ CBR Field density

    Plate load Test Layer Thickness

    Field density DCP Test

    Layer Thickness SPT

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    DCP Test Pressure meter

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    Large Scale Loading

    5.3.5 Hand Penetrometer and Hand Vane for Shear Strength


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    1 Hand penetrometer and hand vane tests shall be carried out where required to give a
    preliminary estimate of undrained shear strength of the soil tested.
    as

    2 Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with
    2
    stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.
    se

    The scale shall be suitably graduated. The procedure for the test shall be in accordance with
    the manufacturer's instructions. Both unconfined compressive strength and estimated shear
    er

    strength shall be reported for the soil tested.


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    3 Hand vane equipment shall be of an approved proprietary make with stainless steel vanes
    having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be
    o

    suitably graduated. The procedure for test shall be in accordance with BS 5930 and the
    it

    manufacturer's instructions. Peak shear strength and residual shear strength shall be
    et

    recorded.
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    4 The reported shear strengths for the hand penetrometer and handvane shall be the average
    of 3 tests in close proximity. Tests giving inconsistent results shall be reported and
    comments on the relevance of the tests noted.

    5.3.6 Self-boring Pressuremeter

    1 The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP)
    unless otherwise designated. The instruments, calibration, operator, installation, testing
    procedure, on-site data processing and analysis, information to be submitted, report data
    processing and analysis and information to be submitted in the report shall be as described
    by Clarke and Smith (1992) and as designated..
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 05: In-Situ Testing, Instrumentation and Monitoring

    5.4 INSTRUMENTATION AND MONITORING

    5.4.1 Groundwater

    1 When groundwater is encountered in exploratory holes, the depth from ground level of the
    point of entry shall be recorded together with depth of any casing. Exploratory hole
    operations shall be stopped and the depth from ground level to water level recorded with an
    approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the
    period of 20 minutes the water level is still rising, this shall be recorded together with the
    depth to water below ground level, unless otherwise instructed by the Engineer, and the
    exploratory hole shall then be continued. If casing is used and this forms a seal against the
    entry of groundwater, the Contractor shall record the depth of casing at which no further entry
    or only insignificant infiltration of water occurred.

    .
    2 Water levels shall be recorded as required by the Contract and at the beginning and end of

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    .l.
    each shift. On each occasion when groundwater levels are recorded, the depth of the
    exploratory hole, the depth of any casing and the time shall also be recorded.

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    3 Where artesian conditions are encountered, the Contractor shall immediately inform the

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    Engineer and agree a method for dealing with the conditions.
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    5.4.2 Installation of Standpipes and Piezometers

    1 Standpipes for monitoring groundwater levels and changes in groundwater levels shall be
    as

    installed in exploratory holes, as instructed by the Engineer. They shall be to the designated
    form and detail, and appropriate dimensions and depths shall be recorded at the time of
    se

    installation.
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    2 Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be


    installed as instructed by the Engineer. They shall be to the designated form and detail, and
    ov

    appropriate dimensions. The installation details of the standpipe piezometers shall be


    recorded.
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    3 The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type
    et

    described in BS 5930 or as designated by the Engineer.


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    5.4.3 Installation of Gas Monitoring Standpipes

    1 Standpipes for monitoring gas concentration in exploratory holes shall be installed as


    instructed by the Engineer. Warning signs or other safety measures required by the Civil
    Defence Department of the Government shall be complied with. Standpipes shall be of the
    designated form and detail. All dimensions and depths shall he recorded at the time of
    installation.

    END OF PART
    QCS 2014 Section 03: Ground Investigation Page 1
    Part 06: Laboratory Testing

    6 LABORATORY TESTING ........................................................................................ 2


    6.1 GENERAL ............................................................................................................... 2
    6.1.1 Scope 2
    6.1.2 References 2
    6.2 SCHEDULE OF TESTS ........................................................................................... 2
    6.3 TESTING PROCEDURES ....................................................................................... 3
    6.3.1 General 3
    6.3.2 Geotechnical Testing on Contaminated Samples 3
    6.3.3 Soil Testing 3
    6.3.4 Rock Testing 3
    6.4 CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4
    6.4.2 Laboratory Testing On Site 6

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    6.4.3 Special Laboratory Testing 6

    .l.
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    et
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    QCS 2014 Section 03: Ground Investigation Page 2
    Part 06: Laboratory Testing

    6 LABORATORY TESTING

    6.1 GENERAL

    6.1.1 Scope

    1 Geotechnical tests and testing procedures carried out in the laboratory or, when designated,
    on site.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, .............. General
    Part 3, .............. Soil Sampling

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    Section 6, ........ Roadworks
    Section 8, ........ Drainage Works

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    Section 12, ...... Earthworks Related to Buildings

    6.1.2 References

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    qa
    1 The following standards and other documents are referred to in this Part:
    ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction
    Purposes
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    ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)


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    ASTM SP 402.............Special Technical Publications No. 402


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    BS 1377 ......................Methods of tests for soils for civil engineering purposes


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    BS 1881 ......................Analysis of hardened concrete


    BS 812 ........................Testing aggregates
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    BS EN 1997--------- .....Ground Investigation and testing


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    et

    Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for
    m

    Rock Mechanics Suggested Methods. 1981. Pergamon Press.


    C2 through C25 and C27 through C31, Methods for examination of waters and associated
    materials, HMSO
    IRSM Commission on Testing Methods. Suggested method for determining Point Load
    Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22,
    51-60 (1985).

    6.2 SCHEDULE OF TESTS

    1 The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be
    necessary to designate additional testing after the results of the original tests are available.
    Unless otherwise agreed, testing schedules are to be provided within six working days of the
    receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the
    Engineer within six working days from the receipt of the approved testing schedule if a
    sample referred to in the schedule is not available for testing.
    QCS 2014 Section 03: Ground Investigation Page 3
    Part 06: Laboratory Testing

    6.3 TESTING PROCEDURES

    6.3.1 General

    1 Where applicable, all preparation, testing and reporting shall be in accordance with the
    relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are
    not covered by these Standards, they shall be performed in accordance with the procedures
    in the references or as designated.

    2 Calibration of load-displacement or other measuring equipment shall be carried out in


    accordance with the relevant standard (the preferred method) or the manufacturers
    instructions by a calibration service approved by the Central Materials Laboratory. Evidence
    of current calibrations shall be supplied to the Engineer.

    .
    6.3.2 Geotechnical Testing on Contaminated Samples

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    1 Where geotechnical testing is required on samples of suspected contaminated material,

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    indicative chemical testing shall be carried out and a safe method of working approved by the
    Engineer before any such work is started. It should be noted that this may include but is not
    limited to the safe storage, transportation and handling of all suspect material.
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    6.3.3 Soil Testing

    1 Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards
    as

    unless otherwise designated.


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    6.3.4 Rock Testing


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    1 Rock testing shall be carried out and reported in accordance with the following references
    and as designated:
    ov

    (a) Classification.
    (i) Natural water content - Brown (1981).
    o

    (ii) Porosity/density - Brown (1981).


    it
    et

    (iii) Void index - Brown (1981).


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    (iv) Carbonate content - BS 1881.


    (v) Petrographic description -Brown (1981).
    (b) Durability.
    (i) Slake durability index - Brown (1981).
    (ii) Soundness by solution of magnesium sulphate - BS 812.
    (c) Hardness.
    (i) Shore sclerometer -Brown (1981).
    (ii) Schmidt rebound hardness - Brown (1981).
    (d) Aggregates.
    (i) Aggregate crushing value - BS 812.
    (ii) Ten percent fines - BS 812.
    (iii) Aggregate impact value - BS 812.
    QCS 2014 Section 03: Ground Investigation Page 4
    Part 06: Laboratory Testing

    (iv) Aggregate abrasion value - BS 812.


    (v) Polished stone value - BS 812.
    (vi) Aggregate frost heave - BS 812.
    (e) Strength.
    (i) Uniaxial compressive strength - Brown (1981).
    (ii) Deformability in uniaxial compression -Brown (1981).
    (iii) Tensile strength-Brown (1981).
    Direct tensile strength.
    Indirect tensile strength by the Brazilian method.
    (iv) Undrained triaxial compression without measurement of porewater pressure-
    Brown (1981).
    (v) Direct shear strength - Brown (1981).

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    (vi) Swelling pressure - Brown (1981).

    rw
    Swelling pressure index under conditions of zero volume change.
    Swelling strain index for a radially confined specimen with axial surcharge.
    Swelling strain developed in an unconfined rock specimen.
    (vii)
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    Point load test - IRSM Commission on Testing Methods (1985).
    qa
    (f) Geophysical.
    (i) Seismic velocity-Brown (1981).
    as

    6.4 CHEMICAL TESTING FOR CONTAMINATED GROUND


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    1 Chemical testing for contaminated ground shall be carried out and reported in accordance
    with the following references and as designated:
    er

    (a) Primary contaminants in soil.


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    (i) Arsenic total - C4.


    (ii) Cadmium total - C2.
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    (iii) Chromium total - C2.


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    (iv) hexavalent chromium (undertaken if total chromium content >25 mg/kg dry
    et

    Mass) -C2.
    m

    (v) Lead total - C2.


    (vi) Mercury total - C3.
    (vii) Selenium total - C4.
    (viii) Boron, water-soluble - C5.
    (ix) Copper total - C2.
    (x) Nickel total - C2.
    (xi) Zinc total - C2.
    (xii) Cyanide total (alkali extraction methods) - C6.
    (xiii) Cyanide complex - C6.
    (xiv) Cyanide free - C6.
    (xv) Thiocyanate - C6.
    QCS 2014 Section 03: Ground Investigation Page 5
    Part 06: Laboratory Testing

    (xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods
    shall follow alkali extraction.)
    (xvii) Phenols total - C7.
    (xviii) Sulphide - C8.
    (xix) Sulphate - total, acid, soluble - C9.
    (xx) Sulphate - water soluble, 2 : 1 extract - C9.
    (xxi) Sulphur free - C10.
    (xxii) PH value - C9.
    (xxiii) Toluene extractable matter - Cl1.
    (xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter>
    2000 g/kg dry mass of soil) - C12.

    .
    (xxv) Asbestos. Asbestos content determination shall be carried out by visual

    l
    examination and polarised light microscopy.

    .l.
    (b) Secondary contaminants in soil.

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    (i) Antimony total - C13.
    (ii) Barium total - C13.
    (iii) Beryllium total - C15. ta
    qa
    (iv) Vanadium total - C13.
    (v) Cyclohexane extractable matter - C14.
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    (vi) Freon extractable matter - C15.


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    (vii) Mineral oils - C31.


    (viii) Chloride - C9.
    er

    (c) Contaminants in water.


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    (i) Arsenic - C4.


    (ii) Cadmium - C2 and C23.
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    (iii) Chromium - C2 and C24.


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    (iv) Hexavalent chromium - C2.


    et

    (v) Lead - C2 and C25.


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    (vi) Mercury - C3.


    (vii) Selenium - C4.
    (viii) Boron - C5 and C6.
    (ix) Copper - C2 and C27.
    (x) Nickel - C2 and C28.
    (xi) Zinc - C2 and C29.
    (xii) Cyanide total - C6.
    (xiii) Cyanide complex - C6.
    (xiv) Cyanide free - C6.
    (xv) Thiocyanate - C6.
    (xvi) Phenols total - C7.
    (xvii) Sulphide - C8.
    QCS 2014 Section 03: Ground Investigation Page 6
    Part 06: Laboratory Testing

    (xviii) Sulphate - C9.


    (xix) Sulphur free - C10.
    (xx) PH value - C9.
    (xxi) Polyaromatic hydrocarbons - C 12.
    (xxii) Antimony-C13.
    (xxiii) Barium-C13.
    (xxiv) Beryllium-C15.
    (xxv) Vanadium - C 13.
    (xxvi) Chloride - C9.
    (xxvii) Ammoniacal nitrogen - C16.
    (xxviii) Nitrate nitrogen - Cl7.

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    (xxix) Chemical oxygen demand - C18.

    .l.
    (xxx) Biochemical oxygen demand - C19.

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    (xxxi) Total organic carbon - C20.
    (xxxii) Volatile fatty acids - C21.
    (xxxiii) Iron - C22.
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    (xxxiv) Manganese - C22.
    (xxxv) Calcium - C31.
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    (xxxvi) Sodium - C31.


    (xxxvii) Magnesium - C31.
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    (xxxviii) Potassium - C21.


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    (d) Constituents of gas samples.


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    (i) Carbon dioxide - C30.


    (ii) Hydrogen - C30.
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    (iii) Hydrogen sulphide - C30.


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    (iv) Methane - C30.


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    (v) Nitrogen - C30.


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    (vi) Oxygen - C30.


    (vii) Ethane- C30.
    (viii) Propane- C30.
    (ix) Carbon monoxide - C30.

    6.4.2 Laboratory Testing On Site

    1 When designated, tests listed under laboratory testing shall be carried out on site.

    6.4.3 Special Laboratory Testing

    1 When designated, special laboratory testing shall be carried out.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 01: General Requirements for Piling Work

    1 GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2


    1.1 GENERAL ............................................................................................................... 2
    1.1.1 Scope 2
    1.1.2 References 2
    1.1.3 General Contract Requirements 2
    1.1.4 Submittals 3
    1.1.5 Records 3
    1.2 GROUND CONDITIONS ......................................................................................... 3
    1.2.1 Ground Investigation Reports 3
    1.2.2 Unexpected Ground Conditions 4
    1.3 MATERIALS AND WORKMANSHIP........................................................................ 4
    1.3.1 General 4

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    1.3.2 Sources of Supply 4

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    1.3.3 Rejected materials 5

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    1.4 INSTALLATION TOLERANCES .............................................................................. 5
    1.4.1 Setting Out 5
    1.4.2
    1.4.3
    Position
    Verticality ta 6
    6
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    1.4.4 Rake 6
    1.4.5 Tolerance Variations 6
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    1.4.6 Forcible Corrections to Pile 6


    1.5 NUISANCE AND DAMAGE ..................................................................................... 6
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    1.5.1 Noise and Disturbance 6


    1.5.2 Damage to Adjacent Structures 7
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    1.5.3 Damage to Piles 7


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    1.5.4 Temporary Support 7


    1.6 SAFETY .................................................................................................................. 7
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    1.6.1 General 7
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    1.6.2 Life-Saving Appliances 7


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    1.6.3 Driving 7
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    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 01: General Requirements for Piling Work

    1 GENERAL REQUIREMENTS FOR PILING WORK

    1.1 GENERAL

    1.1.1 Scope

    1 This Part is concerned with all works associated with installation of piles by any of the
    recognised techniques.

    1.1.2 References

    1 The following standards and codes of practice are referred to in this Part:
    BS 5228......................Noise control on construction and open sites

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    Part I, Code of practice for basic information and procedures for noise

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    control

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    Part IV, Code of practice for noise and vibration control applicable to
    piling operations
    BS 8008......................Safety precautions and procedures for the construction and descent of
    ta
    machine-bored shafts for piling and other purposes
    qa
    BS EN 1997................Eurocode 7, Geotechnical Design.
    as

    1.1.3 General Contract Requirements


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    1 The following matters, where appropriate, are described in the contract specific
    er

    documentation for the Works:


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    (a) general items related to Works


    (i) Nature of the Works.
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    (ii) Classes of loads on piles.


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    et

    (iii) Contract drawings.


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    (iv) Other works proceeding at the same time.


    (v) Working area.
    (vi) Order of the Works.
    (vii) Datum.
    (viii) Offices for the Engineer's Representative.
    (ix) Particular facilities and attendance items where not included in this section.
    (x) Details of soil investigation reports.

    (b) specific items related to particular type of pile


    (i) Soil sampling, laboratory testing and in-situ soil testing.
    (ii) Designed concrete or grout mixes, grades of concrete or grout, type of cement
    and aggregate, grout or concrete admixtures, concreting of piles.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 01: General Requirements for Piling Work

    (iii) Grades and types of reinforcement and prestressing tendons.


    (iv) Pile dimensions, length and marking of piles.
    (v) Type and quality of pile shoe/splice.
    (vi) Type and quality of permanent casing.
    (vii) Specified working loads.
    (viii) Sections of proprietary types of pile, grades of steel, minimum length to be
    supplied, thickness of circumferential weld reinforcement.
    (ix) Surface preparation, types and thickness of coatings.
    (x) Test piles, driving resistance or dynamic evaluation and penetration.
    (xi) Detailed requirements for driving records.

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    (xii) Acceptance criteria for piles under test.

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    (xiii) Disposal of cut-off lengths.

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    (xiv) Preboring.

    1.1.4 Submittals

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    1 The Contractor shall supply for approval all relevant details of the method of piling and the
    plant he proposes to use. Any alternative method to that specified shall be subject to
    approval.
    as

    2 The Contractor shall submit to the Engineer on the first day of each week, or at such longer
    se

    periods as the Engineer may from time to time direct, a progress report showing the current
    rate of progress and progress during the previous period on all important items of each
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    section of the Works.


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    3 The Contractor shall inform the Engineer each day of the intended programme of piling for
    the following day and shall give adequate notice of his intention to work outside normal hours
    and at weekends.
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    1.1.5 Records
    et

    1 The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation
    m

    of each pile and shall submit two signed copies of these records to the Engineer not later
    than noon of the next working day after the pile is installed. The signed records will form a
    record of the work. Any unexpected driving or boring conditions shall be noted briefly in the
    records.

    1.2 GROUND CONDITIONS

    1.2.1 Ground Investigation Reports

    1 Factual information and reports on site investigations for the Works and on the previous
    known uses of the Site will be provided by the Engineer where they exist as part of the
    specific contract documentation. However, even if a full report is given, including
    interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any
    opinions or conclusions which may be given in the reports.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 01: General Requirements for Piling Work

    2 Before the start of work the Contractor shall be given a copy of any subsequent information
    which may have been obtained relating to the ground conditions and previous uses of the
    Site.

    1.2.2 Unexpected Ground Conditions

    1 The Contractor shall report immediately to the Engineer any circumstance which indicates
    that in the Contractor's opinion the ground conditions differ from those reported in or which
    could have been inferred from the site investigation reports or test pile results.

    1.3 MATERIALS AND WORKMANSHIP

    1.3.1 General

    1 All materials and workmanship shall be in accordance with the appropriate British Standards,

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    codes of practice and other approved standards current at the date of tender except where
    the requirements of these standards or codes of practice are in conflict with this Section in

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    which case the requirements of this Section shall take precedence.

    1.3.2 Sources of Supply

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    1 The sources of supply of materials shall not be changed without prior approval.

    Table 1.1
    as

    Records to be Kept (Indicated by an Asterisk)


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    Driven steel, precast

    Driven cast-in-place

    Bored cast-in-place
    concrete and steel

    auger concrete or
    Driven segmental

    Continuous flight
    concrete piles
    concrete piles

    concrete piles
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    sheet piles

    grout piles
    Data
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    Contract * * * * *
    et

    Pile reference number (location) * * * * *


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    Pile type * * * * *
    Nominal cross-sectional dimensions or diameter * * * * *
    Nominal diameter of underream/base - - - * -
    Length of preformed pile * * - - -
    Standing groundwater level from direct observation or given site
    - - * * *
    investigation data.

    Date and time of driving, redriving or boring * * * * *

    Date of concreting - - * * *
    Ground level/sea bed level at pile position at commencement of
    * * * * *
    installation of pile (commencing surface)
    Working elevation of pile driver * * * * *
    Depth from ground level at pile position to pile tip * * * * *
    Tip elevation * * * * *
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 01: General Requirements for Piling Work

    Driven steel, precast

    Driven cast-in-place

    Bored cast-in-place
    concrete and steel

    auger concrete or
    Driven segmental

    Continuous flight
    concrete piles
    concrete piles

    concrete piles
    sheet piles

    grout piles
    Data

    Pile head elevation, as constructed * * * * *


    Pile cut-off elevation * * * * *
    Length of temporary casing - - * * -
    Length of permanent casing - - * * -
    Type, weight, drop and mechanical condition of hammer and
    * * * - -
    equivalent information for other equipment

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    Number and type of packings used and type and condition of
    * * * - -
    dolly used during driving of the pile

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    Set of pile or pile tube in millimetres per 10 blows or number of
    * * * - -
    blows per 25 mm of penetration

    If required, the sets taken at intervals during the last 3 m of


    ta * * * - -
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    driving

    If required, temporary compression of ground and pile from time


    as

    of a marked increase in driving resistance until pile reached its * * * - -


    final level
    se

    If required, driving resistance taken at regular intervals over the


    * * * - -
    last 3 m of driving
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    Soil samples taken and in-situ tests carried out during pile
    * * * * *
    installation
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    Length and details of reinforcements - - * * *


    Concrete mix - - * * *
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    Volume of concrete supplied to pile - - * * *


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    et

    All information regarding obstructions delays and other


    * * * * *
    interruptions to the work
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    1.3.3 Rejected materials

    1 Rejected materials are to be removed promptly from the Site.

    1.4 INSTALLATION TOLERANCES

    1.4.1 Setting Out

    1 Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at
    pile positions, as required by the Contract, shall be located by the Contractor from the main
    grid lines of the proposed structure. Before installation of the pile, the pile position relative to
    the main grid lines shall be verified.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 01: General Requirements for Piling Work

    1.4.2 Position

    1 For a pile cut off at or above ground level the maximum permitted deviation of the pile centre
    from the centre-point shown on the drawings shall be 75 mm in any direction. An additional
    tolerance for a pile head cut off below ground level will be permitted in accordance with
    Clauses 1.4.3 and 1.4.4.

    1.4.3 Verticality

    1 At the commencement of installation, the pile, or pile-forming equipment in the case of a


    driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall
    be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the
    finished pile from the vertical is 1 in 75.

    1.4.4 Rake

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    1 As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of

    rw
    rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The
    piling rig shall be set and maintained to attain the required rake. The maximum permitted
    deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1
    in 15 for piles raking more than 1:6.
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    1.4.5 Tolerance Variations
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    1 In exceptional circumstances where these tolerances are difficult to achieve, the tolerances
    of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of
    se

    the implications of such action.


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    1.4.6 Forcible Corrections to Pile


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    1 Forcible corrections to concrete piles to overcome errors of position or alignment shall not be
    made. Forcible corrections may be made to other piles only if approved and where the pile
    shaft is not fully embedded in the soil.
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    1.5 NUISANCE AND DAMAGE


    et
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    1.5.1 Noise and Disturbance

    1 The Contractor shall carry out the work in such a manner and at such times as to minimise
    noise, vibration and other disturbance in order to comply with current environmental
    legislation.

    2 The Contractor shall endeavour to ascertain the nature and levels of noise produced by the
    mechanical equipment and plant that will be used. He shall than take steps to reduce either
    the level or the annoying characteristics, or both, of the noise. Reference should be made to
    BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment
    and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to
    piling operations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 01: General Requirements for Piling Work

    1.5.2 Damage to Adjacent Structures

    1 If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services
    or adjacent structures, he shall submit to the Engineer his proposals for making
    preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding
    such damage.

    1.5.3 Damage to Piles

    1 The Contractor shall ensure that during the course of the work, displacement or damage
    which would impair either performance or durability does not occur to completed piles.

    2 The Contractor shall submit to the Engineer his proposed sequence and timing for driving or
    boring piles, having the intent of avoiding damage to adjacent piles.

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    1.5.4 Temporary Support

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    rw
    1 The Contractor shall ensure that where required, any permanently free-standing piles are
    temporarily braced or stayed immediately after driving to prevent loosening of the piles in the
    ground and to ensure that the pile will not be damaged by oscillation, vibration or ground
    movement.
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    1.6 SAFETY
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    1.6.1 General
    se

    1 A competent person, properly qualified and experienced, should be appointed to supervise


    the piling operations. This person should be capable of recognising and assessing any
    er

    potential dangers as they arise; e.g., unexpected ground conditions that may require a
    change in construction technique, or unusual smells which may indicate the presence of
    ov

    noxious or dangerous gases.

    2 Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN
    o

    1997. Refer Section 1 for general safety standards to be adopted at a construction site.
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    et

    1.6.2 Life-Saving Appliances


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    1 The Contractor shall provide and maintain on the Site sufficient, proper and efficient life-
    saving appliances to the approval of the Engineer. The appliances must be conspicuous and
    available for use at all times.

    2 Site operatives shall be instructed in the use of safety equipment and periodic drills shall be
    held to ensure that all necessary procedures can be correctly observed.

    1.6.3 Driving

    1 Before any pile driving is started, the Contractor shall supply the Engineer with two copies of
    the code of signals to be employed, and shall have a copy of the code prominently displayed
    adjacent to the driving control station on the craft, structure or site from which the piles will be
    driven.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 02: Concrete Works for Piling

    2 CONCRETE WORKS FOR PILING ......................................................................... 2


    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.1.2 References 2
    2.2 MATERIALS ............................................................................................................ 2
    2.2.1 Cementitious 2
    2.2.2 Aggregate 2
    2.2.3 Water 2
    2.2.4 Admixtures 2
    2.2.5 Steel Reinforcement and Prestressing Steel 2
    2.3 CONCRETE MIXES FOR PILING WORK ............................................................... 3
    2.3.1 General 3

    .
    2.3.2 Grade Designation 3

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    2.3.3 Designed Mix 3

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    2.3.4 Durability 3
    2.3.5 Exposure Classes 3
    2.4
    2.4.1 General ta
    PLACING CONCRETE ............................................................................................ 3
    3
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    2.4.2 Inspection 4
    2.4.3 Cleanliness of Pile Bases 4
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    2.4.4 Workability of Concrete 4


    2.4.5 Compaction 4
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    2.4.6 Placing Concrete in Dry Borings 5


    2.4.7 Placing Concrete under Water or Drilling Fluid 5
    er
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    et
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    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 02: Concrete Works for Piling

    2 CONCRETE WORKS FOR PILING

    2.1 GENERAL

    2.1.1 Scope

    1 This part applies to cast in-situ as well as precast concrete work.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, General Requirements for Piling Work
    Part 3 Shallow Foundations
    Part 4 Deep Foundations

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    Part 5 Retaining Structures

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    Section 5 Concrete.

    2.1.2 References

    1 ta
    The following Standards are referred to in this Part:
    qa
    BS 8008......................Safety precautions and procedures for the construction and descent of
    machine-bored shafts for piling and other purposes
    as

    All Standards mentioned in Section 5


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    2.2 MATERIALS
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    2.2.1 Cementitious
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    1 All cementitious materials shall comply with the requirements of Section 5, Part 3.
    o

    2 All cementitious materials shall be stored in separate containers according to type in


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    waterproof stores or silos.


    et

    2.2.2 Aggregate
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    1 Aggregates shall comply with the requirements of Section 5, Part 2.

    2.2.3 Water

    1 If water for the Works is not available from a public supply, approval shall be obtained
    regarding the source of water. For quality of water refer to Section 5, Part 4.

    2.2.4 Admixtures

    1 Admixtures shall comply with the requirements of Section 5, Part 5

    2.2.5 Steel Reinforcement and Prestressing Steel

    1 Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free
    from loose rust and loose mill scale when installed in the Works. For requirements of steel
    reinforcement refer to Section 5, Part 11.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 02: Concrete Works for Piling

    2 The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in
    reinforcement shall be such that the full strength of each bar is effective across the joint and
    shall be made so that there is no detrimental displacement of the reinforcement during the
    construction of the pile.

    3 For requirements of prestressing steel refer to Section 5, Part 18.

    2.3 CONCRETE MIXES FOR PILING WORK

    2.3.1 General

    1 For general requirements of concrete mixes, trial mixes, batching, mixing and transportation
    of fresh concrete and testing of hardened concrete refer to Section 5.

    2.3.2 Grade Designation

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    1 Grades of concrete shall be as given in Section 5, Part 6.

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    2.3.3 Designed Mix

    1
    ta
    The Contractor shall be responsible for selecting the mix proportions to achieve the required
    qa
    strength and workability..

    2 Complete information on the mix and sources of aggregate for each grade of concrete and
    as

    the water/cementitious ratio and the proposed degree of workability shall be approved before
    work commences.
    se

    3 Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content


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    (equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.
    ov

    4 The Contractor shall submit the slump value for approval before work commences.

    2.3.4 Durability
    it o

    1 For piles exposed to aggressive ground or groundwater, approved measures shall be taken
    et

    to ensure durability. Reference shall be made to Section 5, Part 6.


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    2.3.5 Exposure Classes

    1 The minimum cementitious content and type and the concrete grades shall be specified
    based on the exposure classes as given in Table 6.8, Section 5, Part 6.

    2.4 PLACING CONCRETE

    2.4.1 General

    1 The workability and method of placing and vibrating the concrete shall be such that a
    continuous monolithic concrete shaft of the full cross-section is formed.

    2 The concrete shall be placed without such interruption as would produce a cold joint in the
    pile. The method of placing shall be approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 02: Concrete Works for Piling

    3 The Contractor shall take all precautions in the design of the mix and placing of the concrete
    to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter
    which would adversely affect the performance of the pile shall be permitted to contaminate
    the concrete.

    2.4.2 Inspection

    1 Each pile bore which does not contain standing water or drilling fluid shall be inspected
    directly or indirectly before to concrete is placed in it. This inspection shall be carried out from
    the ground surface in the case of piles of less than 750 mm diameter. Torches or other
    approved means of lighting, measuring tapes, and a means of measuring verticality shall be
    provided. For piles of 750 mm diameter or larger, equipment shall be provided by the
    Contractor to enable his representatives and the Engineer to descend into the bore for the
    purpose of inspection. Any method of descent and the equipment used shall comply with the

    .
    requirements of BS 8008.

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    .l.
    2.4.3 Cleanliness of Pile Bases

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    1 On completion of boring and where inspection of a dry pile bore indicates the necessity,

    ta
    loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain
    water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the
    qa
    concrete shall be placed by tremie method. Large debris or accumulated sediment, or both
    of them, shall be removed using appropriate approved methods, which shall be designed to
    clean while at the same time minimising ground disturbance below the pile bases. Water or
    as

    drilling fluid shall be maintained at such levels throughout and following the cleaning
    operation that stability of the bore is preserved.
    se

    2.4.4 Workability of Concrete


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    1 Slump measured at the time of discharge into the pile bore shall be in accordance with the
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    standards shown in Table 2.1.


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    2.4.5 Compaction
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    et

    1 Internal vibrators may be used to compact concrete, with the approval of the Engineer
    obtained in advance for each specific use.
    m

    Table 2.1
    Standards for Concrete Slump
    Slump
    Piling mix
    Minimum Range Typical conditions of use
    workability
    mm mm
    Placed into water-free unlined or permanently lined bore
    of 600 mm diameter or over, or where concrete is placed
    A 75 75-150 below temporary casing, and where reinforcement is
    widely spaced leaving ample room for free movement of
    concrete between bars.
    Where reinforcement is not spaced widely, where
    B 100 100-200 concrete is placed within temporary casings, where pile
    bore is water-free, and the diameter less than 600 mm
    Where concrete is to be placed by tremie under water or
    C 150 150 or more drilling mud, or by pumping
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 02: Concrete Works for Piling

    2.4.6 Placing Concrete in Dry Borings

    1 Approved measures shall be taken to ensure that the structural strength of the concrete
    placed in all piles is not impaired through grout loss, segregation or bleeding.

    2 Concrete shall be placed by elephant trunk, and the free fall shall not exceed 1.2 m.

    2.4.7 Placing Concrete under Water or Drilling Fluid

    1 Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure
    that there is no accumulation of silt or other material at the base of the boring, and the
    Contractor shall ensure that heavily contaminated bentonite suspension, which could impair
    the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.

    2 Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be

    l .
    discharged freely into the water or drilling fluid. Pumping of concrete may be approved where

    .l.
    appropriate.

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    3 A sample of the bentonite suspension shall be taken from the base of the boring using an
    approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing

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    of concrete shall not proceed. In this event the Contractor shall modify or replace the
    bentonite as approved to meet the specification.
    qa
    4 The concrete shall be a rich, coherent mix and highly workable, and cement content shall be
    as

    in accordance with Clause 2.3.5.


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    5 The concrete shall be placed in such a manner that segregation does not occur.

    6 The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall
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    extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to
    ov

    prevent direct contact between the first charge of concrete in the tremie and the water or
    drilling fluid. The pipe shall at all times penetrate the concrete which has previously been
    placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of
    o

    2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of
    it

    concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that
    et

    from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than
    m

    150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that
    external projections are minimised, allowing the tremie to pass within reinforcing cages
    without causing damage. The internal face of the pipe of the tremie shall be free from
    projections.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 03: Shallow Foundations

    3 SHALLOW FOUNDATIONS .................................................................................... 2


    3.1 GENERAL ............................................................................................................... 2
    3.1.1 Scope 2
    3.1.2 Definition 2
    3.1.3 References 2
    3.1.4 Limit States Considerations 2
    3.2 DESIGN CONSIDERATIONS .................................................................................. 3
    3.2.1 General 3
    3.2.2 Allowable Bearing Pressure 3
    3.2.3 Selection of Types of Shallow Foundation 3
    3.2.4 Pad foundations 4
    3.2.5 Strip foundations 4

    .
    3.2.6 Raft foundations 5

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    3.3 BASIS OF GEOTECHNICAL DESIGN .................................................................... 5

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    3.3.1 Design Requirements 5
    3.3.2 Design Situations 7
    3.3.3 Durability 8
    3.4 ta
    GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9
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    3.4.1 General 9
    3.4.2 Actions 10
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    3.4.3 Ground Properties 12


    3.4.4 Geometrical Data 13
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    3.4.5 Characteristic and Representative Values of Actions 13


    3.4.6 Characteristic Values of Geotechnical Parameters 13
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    3.4.7 Characteristic Values of Geometrical Data 14


    3.4.8 Geotechnical Design Report 14
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    3.4.9 Actions and Design Situations 15


    3.4.10 Design and Construction Considerations 15
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    3.4.11 Foundations on Rock; Additional Design Considerations 16


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    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 03: Shallow Foundations

    3 SHALLOW FOUNDATIONS

    3.1 GENERAL

    3.1.1 Scope

    1 The provisions of this Section apply to shallow foundations including isolated, pads, strips and
    rafts.

    3.1.2 Definition

    1 Shallow foundations are taken to be those where the depth below finished ground level is
    less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is
    arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed

    . l
    as deep foundations.

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    3.1.3 References
    BS 8004,.....................Code of practice for foundations.

    ta
    BS EN 1990................Eurocode 0: Basis of Structural Design
    qa
    BS EN 1991................Eurocode 1: Actions on structures
    BS EN 1992................Eurocode 2: Design of concrete structures -
    BS EN 1993................Eurocode 3: Design of steel structures
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    BS EN 1994................Eurocode 4: Design of composite steel and concrete structures


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    BS EN 1995................Eurocode 5: Design of timber structures


    BS EN 1996................Eurocode 6: Design of masonry structures
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    BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules


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    BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and


    testing
    BS EN 1998................Eurocode 8: Design of structures for earthquake resistance
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    BS 5930......................Code of Practice for Site Investigation


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    et

    3.1.4 Limit States Considerations


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    1 The following limit states shall be considered and an appropriate list shall be compiled:

    (a) Loss of overall stability;


    (b) Bearing resistance failure, punching failure, squeezing;
    (c) Failure by sliding;
    (d) Combined failure in the ground and in the structure;
    (e) Structural failure due to foundation movement;
    (f) Excessive settlements;
    (g) Excessive heave due to swelling, frost and other causes;
    (h) Unacceptable vibrations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 03: Shallow Foundations

    3.2 DESIGN CONSIDERATIONS

    3.2.1 General

    1 The depth to which foundations should be carried depends on two principal factors:

    (a) Reaching an adequate bearing stratum;


    (b) Penetration below the zone in which trouble may be expected from seasonal weather
    changes.

    2 Other factors such as ground movements, changes in groundwater conditions, long-term


    stability and heat transmitted from structures to the supporting ground may be important.

    3 Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose water-
    bearing sands and soils that change structure when loaded. Specialist advice should be

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    sought where such conditions are indicated by ground investigation.

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    3.2.2 Allowable Bearing Pressure

    1 The center of area of a foundation or group of foundations should be arranged vertically

    ta
    under the centre of gravity of the imposed loading. If this is not possible, the effects on the
    qa
    structure of rotation and settlement of the foundation need to be considered.

    2 Where foundation support is provided by a number of separate bases these should, as far as
    as

    practicable, be proportioned so that differential settlement is minimal.


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    3.2.3 Selection of Types of Shallow Foundation


    er

    1 The selection of the appropriate type of shallow foundation will normally depend on the
    magnitude and disposition of the structural loads, the bearing capacity and settlement
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    characteristics of the ground and the need to found in stable soil.

    2 A pad foundation is used for the purpose of distributing concentrated loads. Unless special
    o

    conditions control the design, relatively heavy column loads make it advantageous to use pad
    it

    foundations.
    et

    3 Strip foundations may be more appropriate where column loads are comparatively small and
    m

    closely spaced or where walls are heavy or heavily loaded.

    4 Adjacent pad foundations can be combined or joined together with ground beams to support
    eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns
    may be carried on ground beams spanning between the pad foundations.

    5 Where the allowable bearing pressure would result in large isolated foundations occupying
    the majority of the available area, it may be logical to join them to form a raft and spread the
    loads over the entire area. The combination of isolated foundations to form a raft sometimes
    results in a complex design and a large increase in the reinforcement requirement.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 03: Shallow Foundations

    6 In connection with the provision of foundations to an extension of an existing building,


    allowance should be made for differential movement of the foundations between the new and
    existing structure; such movement affects the structure above foundations. Where a degree
    of cracking and subsequent remedial work is not acceptable, provision for a joint between the
    extension and existing building should be considered. Where the foundations of an extension
    about the foundations of the existing building, the stability of the existing foundations should
    be ensured.

    3.2.4 Pad foundations

    1 For buildings such as low rise dwellings and lightly framed structures, pad foundations may
    be of unreinforced concrete provided that the angle of spread of load from the pier or base
    plate to the outer edge of the ground bearing does not exceed one (vertical) in one
    (horizontal) and that the stresses in the concrete due to bending and shear do not exceed
    tolerable limits. For buildings other than low rise and lightly framed structures, it is customary

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    to use reinforced concrete foundations.

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    2 The thickness of the foundation should under no circumstances be less than 150 mm and will
    generally be greater than this to maintain cover to reinforcement where provided.

    3
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    Where concrete foundations are used they should be designed in accordance with the design
    qa
    method appropriate to the loading assumptions.

    3.2.5 Strip foundations


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    1 Similar considerations to those for pad foundations apply to strip foundations. On sloping
    se

    sites strip foundations should be on a horizontal bearing, stepped where necessary to


    maintain adequate depth.
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    2 In continuous wall foundations it is recommended that reinforcement be provided wherever


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    an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall
    foundations will normally be constructed in mass concrete provided that the angle of spread
    of load from the edge of the wall base to the outer edge of the ground bearing does not
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    exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where
    it

    regarding is likely to take place, may require to be designed as retaining walls to


    et

    accommodate steps between adjacent ground floor slabs or finished ground levels. At all
    m

    changes of level unreinforced foundations should be lapped at the steps for a distance at
    least equal to the thickness of the foundation or a minimum of 300mm. Where the height of
    the step exceeds the thickness of the foundation, special precautions should be taken. The
    thickness of reinforced strip foundations should be not less than 150mm, and care should be
    taken with the excavation levels to ensure that this minimum thickness is maintained. For the
    longitudinal spread of loads, sufficient reinforcement should be provided to withstand the
    tensions induced. It will sometimes be desirable to make strip foundations of inverted tee
    beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners
    and junctions the longitudinal reinforcement of each wall foundation should be lapped.

    3 Where the use of ordinary strip foundations would overstress the bearing strata, wide strip
    foundations designed to transmit the foundation loads across the full width of the strip may be
    used. The depth below the finished ground level should be the same as for ordinary strip
    foundations.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 03: Shallow Foundations

    4 Where the nature of the ground is such that narrow trenches can be neatly cut down to the
    bearing stratum, an economical foundation may be achieved by filling the trenches with
    concrete. When deciding the trench width, account should be taken of normal building
    tolerances in relation to setting out dimensions. Where the thickness of such a foundation is
    500mm or more, any step should be not greater than the concrete thickness and the lap at
    such a step should be at least 1 m or twice the step height, whichever is the greater?

    5 Where fill or other loose materials occur above the bearing stratum adequate support is
    required to any excavation. Consideration may be given to the use of lean mix mass concrete
    replacement under ordinary strip footings placed at shallow depth. This mass concrete can
    be poured against either permanent or recoverable shuttering. This form of foundation
    provides a method of dealing with local areas where deeper foundations are required.

    3.2.6 Raft foundations

    l .
    1 General. Suitably designed raft foundations may be used in the following circumstances.

    .l.
    rw
    (a) For lightly loaded structures on soft natural ground where it is necessary to spread the
    load, or where there is variable support due to natural variations, made ground or
    weaker zones. In this case the function of the raft is to act as a bridge across the

    ta
    weaker zones. Rafts may form part of compensated foundations.
    qa
    (b) Where differential settlements are likely to be significant. The raft will require special
    design, involving an assessment of the disposition and distribution of loads, contact
    pressures and stiffness of the soil and raft.
    as

    3.3 BASIS OF GEOTECHNICAL DESIGN


    se

    3.3.1 Design Requirements


    er

    1 For each geotechnical design situation it shall be verified that no relevant limit state is
    ov

    exceeded.

    2 When defining the design situations and the limit states, the following factors should be
    o

    considered:
    it
    et

    (a) Site conditions with respect to overall stability and ground movements;
    m

    (b) Nature and size of the structure and its elements, including any special requirements
    such as the design life;
    (c) Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities,
    vegetation, hazardous chemicals);
    (d) Ground conditions;
    (e) Ground-water conditions;
    (f) Regional seismicity;
    (g) Influence of the environment (hydrology, surface water, subsidence, seasonal changes
    of temperature and moisture).

    3 Limit states can occur either in the ground or in the structure or by combined failure in the
    structure and the ground.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 03: Shallow Foundations

    4 Limit states should be verified by any appropriate method such as calculation method as
    described in 3.4;

    5 In practice, experience will often show which type of limit state will govern the design and the
    avoidance of other limit states may be verified by a control check.

    6 Buildings should normally be protected against the penetration of ground-water or the


    transmission of vapor or gases to their interiors.

    7 If practicable, the design results should be checked against comparable experience.

    8 In order to establish minimum requirements for the extent and content of geotechnical
    investigations, calculations and construction control checks, the complexity of each
    geotechnical design shall be identified together with the associated risks. In particular, a
    distinction shall be made between:

    l .
    .l.
    (a) L ight and simple structures and small earthworks for which it is possible to ensure that
    the minimum requirements will be satisfied by experience and qualitative geotechnical

    rw
    investigations, with negligible risk;
    (b) Other geotechnical structures.

    9 ta
    For structures and earthworks of low geotechnical complexity and risk, such as defined
    qa
    above, simplified design procedures may be applied.
    as

    10 To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3,


    may be introduced.
    se

    11 A preliminary classification of a structure according to Geotechnical Category should


    normally be performed prior to the geotechnical investigations. The category should be
    er

    checked and changed, if necessary, at each stage of the design and construction process.
    ov

    12 The procedures of higher categories may be used to justify more economic designs, or if the
    designer considers them to be appropriate.
    it o

    13 The various design aspects of a project can require treatment in different Geotechnical
    et

    Categories. It is not required to treat the whole of the project according to the highest of these
    categories.
    m

    14 Geotechnical Category 1 should only include small and relatively simple structures:

    (a) For which it is possible to ensure that the fundamental requirements will be satisfied on
    the basis of experience and qualitative geotechnical investigations;
    (b) With negligible risk.

    15 Geotechnical Category 1 procedures should be used only where there is negligible risk in
    terms of overall stability or ground movements and in ground conditions, which are known
    from comparable local experience to be sufficiently straightforward. In these cases the
    procedures may consist of routine methods for foundation design and construction.

    16 Geotechnical Category 1 procedures should be used only if there is no excavation below the
    water table or if comparable local experience indicates that a proposed excavation below the
    water table will be straightforward.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 03: Shallow Foundations

    17 Geotechnical Category 2 should include conventional types of structure and foundation with
    no exceptional risk or difficult soil or loading conditions

    18 Designs for structures in Geotechnical Category 2 should normally include quantitative


    geotechnical data and analysis to ensure that the fundamental requirements are satisfied.

    19 Routine procedures for field and laboratory testing and for design and execution may be used
    for Geotechnical Category 2 designs.

    (a) the following are examples of conventional structures or parts of structures complying
    with Geotechnical Category 2:
    (i) Shallow foundations;
    (ii) Pile foundations;

    .
    (iii) Walls and other structures retaining or supporting soil or water;

    l
    .l.
    (iv) Excavations;

    rw
    (v) Bridge piers and abutments;
    (vi) Embankments and earthworks;
    (vii)
    ta
    Ground anchors and other tie-back systems;
    qa
    (viii) Tunnels in hard, non-fractured rock and not subjected to special water tightness
    or other requirements.
    as

    20 Geotechnical Category 3 should include structures or parts of structures, which fall outside
    the limits of Geotechnical Categories 1 and 2.
    se

    21 Geotechnical Category 3 should normally include alternative provisions and rules to those in
    er

    this standard.
    ov

    (a) Geotechnical Category 3 includes the following examples:


    (i) Very large or unusual structures;
    o

    (ii) Structures involving abnormal risks, or unusual or exceptionally difficult ground


    it

    or loading conditions;
    et

    (iii) Structures in highly seismic areas;


    m

    (iv) Structures in areas of probable site instability or persistent ground movements


    that require separate investigation or special measures.

    3.3.2 Design Situations

    1 Both short-term and long-term design situations shall be considered.

    2 In geotechnical design, the detailed specifications of design situations should include, as


    appropriate:

    (a) The actions, their combinations and load cases;


    (b) The general suitability of the ground on which the structure is located with respect to
    overall stability and ground movements;
    (c) The disposition and classification of the various zones of soil, rock and elements of
    construction, which are involved in any calculation model;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 8
    Part 03: Shallow Foundations

    (d) Dipping bedding planes;


    (e) Mine workings, caves or other underground structures;
    (f) In the case of structures resting on or near rock:
    (i) inter bedded hard and soft strata;
    (ii) faults, joints and fissures;
    (iii) possible instability of rock blocks;
    (iv) solution cavities, such as swallow holes or fissures filled with soft material, and
    continuing solution processes;
    (g) The environment within which the design is set, including the following:
    (i) effects of scour, erosion and excavation, leading to changes in the geometry of
    the ground surface;

    l .
    .l.
    (ii) effects of chemical corrosion;

    rw
    (iii) effects of weathering;
    (iv) effects of long duration droughts;
    (v)
    ta
    variations in ground-water levels, including, e.g. the effects of dewatering,
    possible flooding, failure of drainage systems, water exploitation;
    qa
    (vi) the presence of gases emerging from the ground;
    as

    (h) Earthquakes;
    (i) Ground movements caused by subsidence due to mining or other activities;
    se

    (j) The sensitivity of the structure to deformations;


    er

    (k) The effect of the new structure on existing structures, services and the local
    environment.
    ov

    3.3.3 Durability
    o

    1 At the geotechnical design stage, the significance of environmental conditions shall be


    it

    assessed in relation to durability and to enable provisions to be made for the protection or
    et

    adequate resistance of the materials.


    m

    2 In designing for durability of materials used in the ground, the following should be considered:

    (a) For concrete:


    (i) Aggressive agents in the ground-water or in the ground or fill material, such as
    acids or sulfate salts;
    (b) For steel:
    (i) Chemical attack where foundation elements are buried in ground that is
    sufficiently permeable to allow the percolation of ground-water and oxygen;
    (ii) Corrosion on the faces of sheet pile walls exposed to free water, particularly in
    the mean water level zone;
    (iii) The pitting type of corrosive attack on steel embedded in fissured or porous
    concrete, particularly for rolled steel where the mill scale, acting as a cathode,
    promotes electrolytic action with the scale-free surface acting as an anode;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 9
    Part 03: Shallow Foundations

    (c) For timber:


    (i) Fungi and aerobic bacteria in the presence of oxygen;
    (d) For synthetic fabrics:
    (i) The ageing effects of UV exposure or ozone degradation or the combined
    effects of temperature and stress, and secondary effects due to chemical
    degradation.

    3 Reference should be made to durability provisions in construction materials standards.

    3.4 GEOTECHNICAL DESIGN BY CALCULATION

    3.4.1 General

    .
    1 Design by calculation shall be in accordance with the fundamental requirements of EN 1990

    l
    .l.
    and with the particular rules of this specification. Design by calculation involves:

    rw
    (a) Actions, which may be either imposed loads or imposed displacements, e.g. from
    ground movements;
    (b) Properties of soils, rocks and other materials;ta
    qa
    (c) Geometrical data;
    (d) Limiting values of deformations, crack widths, vibrations etc;
    as

    (e) Calculation models.


    se

    2 It should be considered that knowledge of the ground conditions depends on the extent and
    quality of the geotechnical investigations. Such knowledge and the control of workmanship
    er

    are usually more significant to fulfilling the fundamental requirements than is precision in the
    ov

    calculation models and partial factors.

    3 The calculation model shall describe the assumed behavior of the ground for the limit state
    o

    under consideration.
    it
    et

    4 If no reliable calculation model is available for a specific limit state, analysis of another limit
    state shall be carried out using factors to ensure that exceeding the specific limit state
    m

    considered is sufficiently improbable. Alternatively, design by prescriptive measures,


    experimental models and load tests, or the observational method, shall be performed.

    5 The calculation model may consist of any of the following:

    (a) An analytical model;


    (b) A semi-empirical model;
    (c) A numerical model.

    6 Any calculation model shall be either accurate or err on the side of safety.

    7 A calculation model may include simplifications.

    8 If needed, a modification of the results from the model may be used to ensure that the design
    calculation is either accurate or errs on the side of safety.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 10
    Part 03: Shallow Foundations

    9 If the modification of the results makes use of a model factor, it should take account of the
    following:

    (a) The range of uncertainty in the results of the method of analysis;


    (b) Any systematic errors known to be associated with the method of analysis.

    10 If an empirical relationship is used in the analysis, it shall be clearly established that it is


    relevant for the prevailing ground conditions.

    11 Limit states involving the formation of a mechanism in the ground should be readily checked
    using a calculation model. For limit states defined by deformation considerations, the
    deformations should be evaluated by calculation or otherwise assessed.

    NOTE: many calculation models are based on the assumption of a sufficiently ductile
    performance of the ground/structure system. A lack of ductility, however, will lead to an

    .
    ultimate limit state characterized by sudden collapse.

    l
    .l.
    12 Numerical methods can be appropriate if compatibility of strains or the interaction between

    rw
    the structure and the soil at a limit state are considered.

    13 Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for

    ta
    the relative stiffness of structure and ground, may be needed in cases where a combined
    qa
    failure of structural members and the ground could occur. Examples include raft foundations,
    laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain
    compatibility for materials that are brittle or that have strain-softening properties.
    as

    14 In some problems, such as excavations supported by anchored or strutted flexible walls, the
    se

    magnitude and distribution of earth pressures, internal structural forces and bending
    moments depend to a great extent on the stiffness of the structure, the stiffness and strength
    er

    of the ground and the state of stress in the ground.


    ov

    15 In these problems of ground-structure interaction, analyses should use stress-strain


    relationships for ground and structural materials and stress states in the ground that are
    sufficiently representative, for the limit state considered, to give a safe result.
    it o

    3.4.2 Actions
    et

    1 The definition of actions shall be taken as:


    m

    (a) Set of forces (loads) applied to the structure (direct action);


    (b) Set of imposed deformations or accelerations caused for example, by temperature
    changes, moisture variation, uneven settlement or earthquakes (indirect action).
    The values of actions shall be taken from EN 1991 or equivalent international standard,
    where relevant.

    2 The values of geotechnical actions to be used shall be selected, since they are known before
    a calculation is performed; they may change during that calculation.

    NOTE: Values of geotechnical actions may change during the course of calculation. In such
    cases they will be introduced as a first estimate to start the calculation with a preliminary,
    known value.

    3 Any interaction between the structure and the ground shall be taken into account when
    determining the actions to be adopted in the design.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 11
    Part 03: Shallow Foundations

    4 In geotechnical design, the following should be considered for inclusion as actions:

    (a) the weight of soil, rock and water;


    (b) stresses in the ground;
    (c) earth pressures and ground-water pressure;
    (d) free water pressures, including wave pressures;
    (e) ground-water pressures;
    (f) seepage forces;
    (g) dead and imposed loads from structures;
    (h) surcharges;
    (i) mooring forces;

    l .
    (j) removal of load or excavation of ground;

    .l.
    (k) traffic loads;

    rw
    (l) movements caused by mining or other caving or tunneling activities;
    (m)
    ta
    swelling and shrinkage caused by vegetation, climate or moisture changes;
    qa
    (n) movements due to creeping or sliding or settling ground masses;
    (o) movements due to degradation, dispersion, decomposition, self-compaction and
    solution;
    as

    (p) movements and accelerations caused by earthquakes, explosions, vibrations and


    se

    dynamic loads;
    (q) temperature effects, including frost action;
    er

    (r) imposed pre-stress in ground anchors or struts;


    ov

    (s) down drag.

    5 Consideration shall be given to the possibility of variable actions occurring both jointly and
    o

    separately.
    it
    et

    6 The duration of actions shall be considered with reference to time effects in the material
    m

    properties of the soil, especially the drainage properties and compressibility of fine-grained
    soils.

    7 Actions, which are applied repeatedly, and actions with variable intensity shall be identified
    for special consideration with regard to, e.g. continuing movements, liquefaction of soils,
    change of ground stiffness and strength.

    8 Actions that produce a dynamic response in the structure and the ground shall be identified
    for special consideration.

    9 Actions in which ground- and free-water forces predominate shall be identified for special
    consideration with regard to deformations, fissuring, variable permeability and erosion.

    NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in
    some situations be considered as coming from a single source. If they are considered so, a
    single partial factor may be applied to the sum of these actions or to the sum of their effects.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 12
    Part 03: Shallow Foundations

    3.4.3 Ground Properties

    1 Properties of soil and rock masses, as quantified for design calculations by geotechnical
    parameters, shall be obtained from test results, either directly or through correlation, theory
    or empiricism, and from other relevant data.

    2 Values obtained from test results and other data shall be interpreted appropriately for the limit
    state considered.

    3 Account shall be taken of the possible differences between the ground properties and
    geotechnical parameters obtained from test results and those governing the behavior of the
    geotechnical structure.

    4 The above differences can be due to the following factors:

    .
    (a) many geotechnical parameters are not true constants but depend on stress level and

    l
    .l.
    mode of deformation;

    rw
    (b) soil and rock structure (e.g. fissures, laminations, or large particles) that may play a
    different role in the test and in the geotechnical structure;
    (c) time effects;
    ta
    qa
    (d) the softening effect of percolating water on soil or rock strength;
    (e) the softening effect of dynamic actions;
    as

    (f) the brittleness or ductility of the soil and rock tested;


    (g) the method of installation of the geotechnical structure;
    se

    (h) the influence of workmanship on artificially placed or improved ground;


    er

    (i) the effect of construction activities on the properties of the ground.


    ov

    5 When establishing values of geotechnical parameters, the following should be considered:

    (a) published and well recognized information relevant to the use of each type of test in
    o

    the appropriate ground conditions;


    it
    et

    (b) the value of each geotechnical parameter compared with relevant published data and
    local and general experience;
    m

    (c) the variation of the geotechnical parameters that are relevant to the design;
    (d) the results of any large scale field trials and measurements from neighboring
    constructions;
    (e) any correlations between the results from more than one type of test;
    (f) any significant deterioration in ground material properties that may occur during the
    lifetime of the structure.

    6 Calibration factors shall be applied where necessary to convert laboratory or field test results
    according to EN 1997-2 into values that represent the behavior of the soil and rock in the
    ground, for the actual limit state, or to take account of correlations used to obtain derived
    values from the test results.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 13
    Part 03: Shallow Foundations

    3.4.4 Geometrical Data

    1 The level and slope of the ground surface, water levels, levels of interfaces between strata,
    excavation levels and the dimensions of the geotechnical structure shall be treated as
    geometrical data.

    3.4.5 Characteristic and Representative Values of Actions

    1 Characteristic and representative values of actions shall be derived in accordance with EN


    1990:2002 and the various parts of EN 1991.

    3.4.6 Characteristic Values of Geotechnical Parameters

    1 The selection of characteristic values for geotechnical parameters shall be based on results
    and derived values from laboratory and field tests, complemented by well-established

    l .
    experience.

    .l.
    rw
    2 The characteristic value of a geotechnical parameter shall be selected as a cautious estimate
    of the value affecting the occurrence of the limit state.

    3
    ta
    The selection of characteristic values for geotechnical parameters shall take account of the
    following:
    qa
    (a) geological and other background information, such as data from previous projects;
    as

    (b) the variability of the measured property values and other relevant information, e.g.
    from existing knowledge;
    se

    (c) the extent of the field and laboratory investigation;


    er

    (d) the type and number of samples;


    (e) the extent of the zone of ground governing the behavior of the geotechnical structure
    ov

    at the limit state being considered;


    (f) the ability of the geotechnical structure to transfer loads from weak to strong zones in
    o

    the ground.
    it
    et

    4 Characteristic values can be lower values, which are less than the most probable values, or
    upper values, which are greater.
    m

    5 For each calculation, the most unfavorable combination of lower and upper values of
    independent parameters shall be used.

    6 The zone of ground governing the behavior of a geotechnical structure at a limit state is
    usually much larger than a test sample or the zone of ground affected in an in situ test.
    Consequently the value of the governing parameter is often the mean of a range of values
    covering a large surface or volume of the ground. The characteristic value should be a
    cautious estimate of this mean value.

    7 If the behavior of the geotechnical structure at the limit state considered is governed by the
    lowest or highest value of the ground property, the characteristic value should be a cautious
    estimate of the lowest or highest value occurring in the zone governing the behavior.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 14
    Part 03: Shallow Foundations

    8 When selecting the zone of ground governing the behavior of a geotechnical structure at a
    limit state, it should be considered that this limit state may depend on the behavior of the
    supported structure. For instance, when considering a bearing resistance ultimate limit state
    for a building resting on several footings, the governing parameter should be the mean
    strength over each individual zone of ground under a footing, if the building is unable to resist
    a local failure. If, however, the building is stiff and strong enough, the governing parameter
    should be the mean of these mean values over the entire zone or part of the zone of ground
    under the building.

    9 If statistical methods are employed in the selection of characteristic values for ground
    properties, such methods should differentiate between local and regional sampling and
    should allow the use of a prior knowledge of comparable ground properties.

    10 If statistical methods are used, the characteristic value should be derived such that the
    calculated probability of a worse value governing the occurrence of the limit state under

    l .
    consideration is not greater than 5%.

    .l.
    rw
    NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean
    value of the limited set of geotechnical parameter values, with a confidence level of 95%;
    where local failure is concerned, a cautious estimate of the low value is a 5% fractal.

    11
    ta
    When using standard tables of characteristic values related to soil investigation parameters,
    qa
    the characteristic value shall be selected as a very cautious value.

    3.4.7 Characteristic Values of Geometrical Data


    as

    1 Characteristic values of the levels of ground and ground-water or free water shall be
    se

    measured, nominal or estimated upper or lower levels.


    er

    2 Characteristic values of levels of ground and dimensions of geotechnical structures or


    elements should usually be nominal values.
    ov

    3.4.8 Geotechnical Design Report


    o

    1 The assumptions, data, methods of calculation and results of the verification of safety and
    it

    serviceability shall be recorded in the Geotechnical Design Report.


    et

    2 The level of detail of the Geotechnical Design Reports will vary greatly, depending on the
    m

    type of design. For simple designs, a single sheet may be sufficient.

    3 The Geotechnical Design Report should normally include the following items, with cross-
    reference to the Ground Investigation Report :

    (a) a description of the site and surroundings;


    (b) a description of the ground conditions;
    (c) a description of the proposed construction, including actions;
    (d) design values of soil and rock properties, including justification, as appropriate;
    (e) statements on the codes and standards applied;
    (f) statements on the suitability of the site with respect to the proposed construction and
    the level of acceptable risks;
    (g) geotechnical design calculations and drawings;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 15
    Part 03: Shallow Foundations

    (h) foundation design recommendations;


    (i) a note of items to be checked during construction or requiring maintenance or
    monitoring.

    4 The Geotechnical Design Report shall include a plan of supervision and monitoring, as
    appropriate. Items, which require checking during construction or, which require maintenance
    after construction shall be clearly identified. When the required checks have been carried out
    during construction, they shall be recorded in an addendum to the Report.

    5 In relation to supervision and monitoring the Geotechnical Design Report should state:

    (a) the purpose of each set of observations or measurements;


    (b) the parts of the structure, which are to be monitored and the locations at which
    observations are to be made;

    l .
    (c) the frequency with which readings is to be taken;

    .l.
    (d) the ways in which the results are to be evaluated;

    rw
    (e) the range of values within which the results are to be expected;
    (f)
    (g) ta
    the period of time for which monitoring is to continue after construction is complete;
    the parties responsible for making measurements and observations, for interpreting
    qa
    the results obtained and for maintaining the instruments.

    6 An extract from the Geotechnical Design Report, containing the supervision, monitoring and
    as

    maintenance requirements for the completed structure, shall be provided to the owner/client.
    se

    3.4.9 Actions and Design Situations


    er

    1 Design situations shall be selected in accordance with 3.3.2.


    ov

    2 The actions listed in 3.4.2(4) should be considered when selecting the limit states for
    calculation.
    it o

    3 If structural stiffness is significant, an analysis of the interaction between the structure and
    et

    the ground should be performed in order to determine the distribution of actions.


    m

    3.4.10 Design and Construction Considerations

    1 When choosing the depth of a shallow foundation the following shall be considered:

    (a) reaching an adequate bearing stratum;


    (b) the depth above which shrinkage and swelling of clay soils, due to seasonal weather
    changes, or to trees and shrubs, may cause appreciable movements;
    (c) the level of the water table in the ground and the problems, which may occur if
    excavation for the foundation is required below this level;
    (d) possible ground movements and reductions in the strength of the bearing stratum by
    seepage or climatic effects or by construction procedures;
    (e) the effects of excavations on nearby foundations and structures;
    (f) anticipated excavations for services close to the foundation;
    (g) high or low temperatures transmitted from the building;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 16
    Part 03: Shallow Foundations

    (h) the possibility of scour;


    (i) the effects of variation of water content due to long periods of drought, and subsequent
    periods of rain, on the properties of volume-unstable soils in arid climatic areas;
    (j) the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;

    2 In addition to fulfilling the performance requirements, the design foundation width shall take
    account of practical considerations such as economic excavation, setting out tolerances,
    working space requirements and the dimensions of the wall or column supported by the
    foundation.

    3 One of the following design methods shall be used for shallow foundations:

    (a) a direct method, in which separate analyses are carried out for each limit state. When
    checking against an ultimate limit state, the calculation shall model as closely as

    .
    possible the failure mechanism, which is envisaged. When checking against a

    l
    .l.
    serviceability limit state, a settlement calculation shall be used;

    rw
    (b) an indirect method using comparable experience and the results of field or laboratory
    measurements or observations, and chosen in relation to serviceability limit state loads
    so as to satisfy the requirements of all relevant limit states;
    (c) ta
    a prescriptive method in which a presumed bearing resistance is used.
    qa
    3.4.11 Foundations on Rock; Additional Design Considerations
    as

    1 The design of shallow foundations on rock shall take account of the following features:
    se

    (a) the deformability and strength of the rock mass and the permissible settlement of the
    supported structure;
    er

    (b) the presence of any weak layers, for example solution features or fault zones, beneath
    the foundation;
    ov

    (c) the presence of bedding joints and other discontinuities and their characteristics (for
    example filling, continuity, width, spacing);
    it o

    (d) the state of weathering, decomposition and fracturing of the rock;


    et

    (e) disturbance of the natural state of the rock caused by construction activities, such as,
    for example, underground works or slope excavation, being near to the foundation.
    m

    2 Shallow foundations on rock may normally be designed using the method of presumed
    bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and
    sandstones, the presumed bearing pressure are limited by the compressive strength of the
    concrete foundation.

    3 The settlement of a foundation may be assessed on the basis of comparable experience


    related to rock mass classification.

    END OF PART
    QCS 2014 Section 04: Foundations and Retaining Structures Page 1
    Part 04: Deep Foundations

    4 DEEP FOUNDATIONS ............................................................................................ 4


    4.1 PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4
    4.1.1 General 4
    4.1.2 Limit States Considerations 4
    4.1.3 Precast Reinforced and Prestressed Concrete Piles 4
    4.1.4 Materials and components 5
    4.1.5 Prestressing 7
    4.1.6 Driving Piles 8
    4.1.7 Risen Piles 10
    4.1.8 Repair and lengthening of piles 10
    4.1.9 Cutting off pile heads 10
    4.2 PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10

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    4.2.1 Scope 10
    4.2.2 References 11

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    4.2.3 Submittals 11
    4.2.4 Quality Assurance 11
    4.2.5
    4.2.6
    Tolerances in Pile Dimensions
    Handling, Transportation, Storage and Acceptance of Piles ta 11
    12
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    4.2.7 Materials and components 12
    4.2.8 Driving piles 13
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    4.2.9 Risen Piles 14


    4.2.10 Repair and lengthening of piles 15
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    4.2.11 Cutting off pile heads 15


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    4.3 BORED CAST IN PLACE PILES ........................................................................... 15


    4.3.1 Scope 15
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    4.3.2 References 16
    4.3.3 Quality Assurance 16
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    4.3.4 Materials 16
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    4.3.5 Boring 17
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    4.3.6 Extraction of casing 19


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    4.4 BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND


    CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21
    4.4.1 Scope 21
    4.4.2 Materials 21
    4.4.3 Boring 22
    4.4.4 Placing of concrete or grout 23
    4.4.5 Cutting off pile heads 23
    4.5 DRIVEN CAST IN PLACES PILES ........................................................................ 23
    4.5.1 Scope 23
    4.5.2 Submittals 24
    4.5.3 Quality Assurance 24
    4.5.4 Materials 24
    4.5.5 Driving piles 25
    4.5.6 Risen Piles 26
    QCS 2014 Section 04: Foundations and Retaining Structures Page 2
    Part 04: Deep Foundations

    4.5.7 Extraction of casing 26


    4.6 STEEL PILES ........................................................................................................ 28
    4.6.1 Scope 28
    4.6.2 References 28
    4.6.3 Submittals 28
    4.6.4 Quality Assurance 28
    4.6.5 Delivery, Storage and Handling 29
    4.6.6 Materials 29
    4.6.7 Acceptance Standards For Welds 30
    4.6.8 Acceptability and inspection of coatings 31
    4.6.9 Driving of piles 31
    4.6.10 Risen Piles 33
    4.6.11 Preparation of pile heads 33

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    4.7 MICROPILES (TO BE ADDED LATER) ................................................................. 33
    4.8 REDUCTION OF FRICTION ON PILES ................................................................ 33

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    4.8.1 Scope 33
    4.8.2 Submittals 33
    4.8.3 Friction Reducing Methods
    ta 33
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    4.8.4 Inspection 34
    4.8.5 Driving resistance 35
    4.9 PILE LOAD TESTING ........................................................................................... 35
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    4.9.1 Static Load Testing of Piles 35


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    4.9.2 Presentation of results 45


    4.9.3 Low strain Integrity test 47
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    4.9.4 Grosshole Sonic Logging Test 48


    4.9.5 Calliper Logging Test 48
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    4.9.6 Axial Tensile Load Test 48


    4.9.7 Lateral Load Test 48
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    4.9.8 Alternative Methods for Testing Piles 48


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    4.10 DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51


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    4.10.1 Design method 51


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    4.10.2 Verification of Resistance for Structural and Ground Limit States in Persistent and
    Transient Situations 51
    4.10.3 Design Considerations 51
    4.11 AXIALLY LOADED PILES ..................................................................................... 52
    4.11.1 Limit state design 52
    4.11.2 Compressive Ground Resistance 53
    4.11.3 Ultimate compressive resistance from static load tests 54
    4.11.4 Ultimate compressive resistance from ground test results 55
    4.11.5 Ultimate compressive resistance from dynamic impact tests 56
    4.11.6 Ultimate compressive resistance by applying pile driving formulae 56
    4.11.7 Ultimate compressive resistance from wave equation analysis 56
    4.11.8 Ground tensile resistance 57
    4.11.9 Ultimate tensile resistance from pile load tests 57
    4.11.10 Ultimate tensile resistance from ground test results 57
    QCS 2014 Section 04: Foundations and Retaining Structures Page 3
    Part 04: Deep Foundations

    4.11.11 Vertical displacements of pile foundations 58


    4.11.12 Pile foundations in compression 58
    4.11.13 Pile foundations in tension 58
    4.12 TRANSVERSELY LOADED PILES ....................................................................... 58
    4.12.1 Design method 58
    4.12.2 Transverse load resistance from pile load tests 59
    4.12.3 Transverse load resistance from ground test results and pile strength parameters 59
    4.12.4 Transverse displacement 60

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    QCS 2014 Section 04: Foundations and Retaining Structures Page 4
    Part 04: Deep Foundations

    4 DEEP FOUNDATIONS

    4.1 PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES

    4.1.1 General

    1 The provisions of this Part apply to end-bearing piles, friction piles, tension piles and
    transversely loaded piles installed by driving, by jacking, and by screwing or boring with or
    without grouting.

    4.1.2 Limit States Considerations

    1 The following limit states shall be considered and an appropriate list shall be compiled:

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    (a) Loss of overall stability;

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    (b) bearing resistance failure of the pile foundation;

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    (c) Uplift or insufficient tensile resistance of the pile foundation;
    (d) Failure in the ground due to transverse loading of the pile foundation;
    (e)
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    Structural failure of the pile in compression, tension, bending, buckling or shear;
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    (f) combined failure in the ground and in the pile foundation;
    (g) combined failure in the ground and in the structure;
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    (h) Excessive settlement;


    (i) Excessive heave;
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    (j) Excessive lateral movement;


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    (k) Unacceptable vibrations.


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    4.1.3 Precast Reinforced and Prestressed Concrete Piles

    1 Scope
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    (a) This Part applies to precast concrete driven piles usually supplied for use in a single
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    length without facility for joining lengths together.


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    (b) Related Sections and Parts are as follows:

    2 References

    (a) The following Standards are referred to in this Part:


    BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates
    BS 3100,.....................Steel castings for general engineering purposes
    BS 2789,.....................Spheroidal graphite or nodular graphite cast iron
    BS 8110,.....................Structural use of concrete.

    3 Submittals

    (a) The Contractor shall order the piles to suit the construction programme and seek the
    Engineer's approval before placing the order. When preliminary piles are specified,
    the approval of the piles for the main work will not necessarily be given until the results
    of the driving and loading tests on preliminary piles have been received and evaluated.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 5
    Part 04: Deep Foundations

    4 Quality Assurance

    (a) After a pile has been cast, the date of casting, reference number, length and, where
    appropriate, the prestressing force shall be clearly inscribed on the top surface of the
    pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall
    be marked at the proper locations on each pile.

    5 Tolerances in Pile Dimensions

    (a) The cross-sectional dimensions of the pile shall be not less than those specified and
    shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by
    more than 6 mm from any straight line 3 m long joining two points on that face, nor
    shall the centre of area of the pile at any cross section along its length deviate by more
    than 1/500 of the pile length from a line joining the centres of area at the ends of the

    .
    pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall

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    be reduced below 6 mm on a pro rata basis in accordance with actual length.

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    6 Handling, Transportation and Storage of Piles

    (a) The method and sequence of lifting, handling, and storage of piles transporting and

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    storing piles shall be such as to avoid shock loading and to ensure that the piles are
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    not damaged. Only the designated lifting and support points shall be used. During
    transport and storage, piles shall be appropriately supported under the marked lifting
    points or fully supported along their length.
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    (b) All piles within a stack shall be in groups of the same length. Packing of uniform
    thickness shall be provided between piles at the lifting points.
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    (c) Concrete shall at no time be subjected to loading, including its own weight, which will
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    induce a compressive stress in it exceeding 0.33 of its strength at the time of loading
    or of the specified strength, whichever is the lesser. For this purpose the assessment
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    of the strength of the concrete and of the stresses produced by the loads shall be
    subject to the agreement of the Engineer.
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    (d) Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The
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    measurement shall be made with the pile in its working attitude.


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    4.1.4 Materials and components


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    1 Fabricated Steel Components

    (a) In the manufacture of precast concrete piles, fabricated steel components shall comply
    with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and
    ductile iron components with BS 2789.

    2 Pile Toes

    (a) Pile toes shall be constructed so as to ensure that damage is not caused to the pile
    during installation. Where positional fixity is required on an inclined rock surface or in
    other circumstances, an approved shoe may be required.

    3 Pile Head Reinforcement

    (a) The head of each pile shall be so reinforced or banded as to prevent bursting of the
    pile under driving conditions.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 6
    Part 04: Deep Foundations

    4 Main Reinforcement

    (a) The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in
    one continuous length unless otherwise specified. In piles more than 12 m long, lap
    splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no
    more than 25 % of the bars lapped at one location, and laps staggered by a minimum
    of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is
    effective across the joint.
    (b) Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.
    (c) Sufficient reinforcement shall be provided for lifting and handling purposes.

    5 Concrete

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    (a) Unless otherwise agreed by the Engineer, concrete shall be compacted with the

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    assistance of vibrators. Internal vibrators shall be capable of producing not less than

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    150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not
    closer than 75 mm to shuttering.

    (b)
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    Vibrators shall be operated in such a manner that neither segregation of the concrete
    mix constituents nor displacement of reinforcement occurs.
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    (c) Immediately after compaction, concrete shall he adequately protected from the harmful
    effects of the weather, including wind, rain, rapid temperature changes and frost. It
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    shall be protected from drying out by an approved method of curing.


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    (d) Piles shall not be removed from formwork until a sufficient pile concrete strength has
    been achieved to allow the pile to be handled without damage.
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    (e) The period of curing at an ambient temperature of 10 C shall not be less than that
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    shown in Table 4.1. If the temperature is greater or less than 10 C, the periods given
    shall be adjusted accordingly and shall be approved.
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    (f) When steam or accelerated curing is used the curing procedure shall be approved.
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    Four hours must elapse from the completion of placing concrete before the
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    temperature is raised. The rise in temperature within any period of 30 min shall not
    exceed 10 C and the maximum temperature attained shall not exceed 70 C. The rate
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    of subsequent cooling shall not exceed the rate of heating.

    Table 4.1
    Period of Curing at 10 C
    Wet curing time after
    Type of cement
    completion of placing concrete, d

    Ordinary Portland 4
    Sulphate-resisting Portland 4
    Portland blast-furnace 4
    Super-sulphated 4
    Rapid-hardening Portland 3
    QCS 2014 Section 04: Foundations and Retaining Structures Page 7
    Part 04: Deep Foundations

    6 Formwork

    (a) shaped point or shoe, then the end of the pile shall be symmetrical about the
    longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile,
    shall be lined with steel tubes; alternatively, approved inserts may be cast in.
    (b) Formwork shall be robust, clean and so constructed as to prevent loss of grout or
    aggregate from the wet concrete and ensure the production of uniform pile sections,
    free from defects. The piles are to be removed from the formwork carefully so as to
    prevent damage.

    4.1.5 Prestressing

    1 General

    (a) Tensioning shall be carried out only when the Engineer is present, unless otherwise

    .
    approved. In cases where piles are manufactured off site, the Contractor shall ensure

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    that the Engineer is given adequate notice and every facility for inspecting the
    manufacturing process.

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    (b) Prestressing operations shall be carried out only under the direction of an experienced
    and competent supervisor. All personnel operating the stressing equipment shall have

    (c)
    been trained in its use.
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    The calculated extensions and total forces, including allowance for losses, shall be
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    agreed with the Engineer before stressing is commenced.
    (d) Stressing of tendons and transfer of prestress shall be carried out at a gradual and
    as

    steady rate. The force in the tendons shall be obtained from readings on a recently
    calibrated load cell or pressure gauge incorporated in the equipment. The extension of
    the tendons under the agreed total forces shall be within 5 % of the agreed calculated
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    extension.
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    2 Concrete Strength
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    (a) The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to
    be able to demonstrate by testing two cubes at a time, with approved intervals between
    pairs of cubes, that the specified transfer strength of the concrete has been reached.
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    (b) Unless otherwise permitted, concrete shall not be stressed until two test cubes attain
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    the specified transfer strength.


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    3 Post-Tensioned Piles

    (a) Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.

    4 Grouting Procedure

    (a) Grout shall be mixed for a minimum of 2 min and until a uniform consistency is
    obtained.
    (b) Ducts shall not be grouted when the air temperature in the shade is lower than 3 C.

    (c) Before grouting is started all ducts shall be thoroughly cleaned by means of
    compressed air.
    (d) Grout shall be injected near the lowest point in the duct in one continuous operation
    and allowed to flow from the outlet until the consistency is equivalent to that of the
    grout being injected.
    (e) Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 8
    Part 04: Deep Foundations

    5 Grout

    (a) Unless otherwise directed or agreed by the Engineer


    (i) the grout shall consist only of ordinary Portland cement, water and approved
    admixtures; admixtures containing chlorides or nitrates shall not be used
    (ii) the grout shall have a water/cement ratio as low as possible consistent with the
    necessary workability, and the water/cement ratio shall not exceed 0.45 unless
    an approved mix containing an expanding agent is used
    (iii) the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess
    of 4% maximum, when measured at 18 C in a covered glass cylinder
    approximately 100 mm in diameter with a height of grout of approximately 100
    mm, and the water shall be reabsorbed after 24 h.

    6 Records

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    (a) The Contractor shall keep detailed records of times of tensioning, measured

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    extensions, pressure gauge readings or load cell readings and the amount of pull-in at

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    each anchorage. Copies of these records shall be supplied to the Engineer within
    such reasonable time from completion of each tensioning operation as may be
    required, and in any case not later than noon on the following working day.
    (b)
    ta
    The Contractor shall keep records of grouting, including the date, the proportions of
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    the grout and any admixtures used, the pressure, details of interruption and topping up
    required. Copies of these records shall be supplied to the Engineer within such
    reasonable time after completion of each grouting operation as may be required, and
    as

    in any case not later than noon on the following working day.
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    4.1.6 Driving Piles


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    1 Strength of Piles
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    (a) Piles shall not be driven until the concrete has achieved the specified strength.

    2 Leaders and Trestles


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    (a) At all stages during driving and until incorporation into the substructure, the pile shall
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    be adequately supported and restrained by means of leaders, trestles, temporary


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    supports or other guide arrangements to maintain position and alignment and to


    prevent buckling. These arrangements shall be such that damage to the pile does not
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    occur.

    3 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment. Where designated, dynamic evaluation and analysis
    shall be provided.
    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile unless otherwise approved by the Engineer. For other types of hammer the
    energy delivered to the pile per blow shall be at least equivalent to that of a drop
    hammer of the stated mass. Drop hammers shall not be used from floating craft in
    such a manner as to cause instability of the craft or damage to the pile.

    4 Length of Piles

    (a) The length of pile to be driven in any location shall be approved prior to the
    commencement of driving.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 9
    Part 04: Deep Foundations

    5 Driving Procedure and Redrive Checks

    (a) The driving of each pile shall be continuous until the specified depth or resistance
    (set), or both, has been reached. In the event of unavoidable interruption to driving,
    the pile will be accepted provided it can subsequently be driven to the specified depth
    or resistance (set), or both, without damage. A follower shall not be used unless
    approved, in which case the Engineer will require the set where applicable to be
    revised in order to take into account reduction in the effectiveness of the hammer blow.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    driving characteristics is noted. A detailed record of the driving resistance over the full
    length of the nearest available pile shall be taken if required.
    (c) At the start of the work in a new area or section, a detailed driving record shall be
    made over the full length of the first pile and during the last 3 m of subsequent piles
    until consistency of behaviour is established. Where required, detailed driving records

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    shall also be made for 5 % of the piles driven, the locations of such piles being
    specified by the Engineer.

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    (d) The Contractor shall give adequate notice and provide all necessary facilities to enable
    the Engineer to check driving resistance. A set or resistance measurement shall be

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    taken only in the presence of the Engineer unless otherwise approved.
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    (e) Redrive checks, if required, shall be carried out to an approved procedure.

    6 Final Set
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    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
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    penetration in millimetres per 10 blows or as the number of blows required to produce


    a penetration of 25 mm.
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    (b) When a final set is being measured, the following requirements shall be met:
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    (i) The exposed part of the pile shall be in good condition without damage or
    distortion.
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    (ii) The helmet, dolly and any packing shall be in sound condition.
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    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
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    be flat and at right angles to the pile and hammer axis, and the head of the pile
    protected against damage from hammer impact.
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    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded, if required.

    7 Preboring

    (a) If preboring is specified, the diameter and depth of prebore shall be as designated.

    8 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 10
    Part 04: Deep Foundations

    4.1.7 Risen Piles

    (a) Piles shall be driven in an approved sequence to minimise the detrimental effects of
    heave and lateral displacement of the ground.
    (b) When required, levels and measurements shall be taken to determine the movement
    of the ground or of any pile resulting from the driving process.
    (c) When a pile has risen as a result of adjacent piles being driven, the Engineer may call
    for redriving or other testing to demonstrate that the performance of the pile is
    unimpaired. If required, the Contractor shall make proposals for correcting
    detrimentally affected piles and for avoidance or control of heave effects in subsequent
    work.

    4.1.8 Repair and lengthening of piles

    .
    1 Repair of Damaged Pile Heads

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    (a) If it is necessary to repair the head of a pile during driving, the Contractor shall carry

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    out such repair in an approved way which allows the pile-driving to be completed
    without further damage. If the driving of a pile has been accepted but sound concrete
    of the pile is below the required cut-off level, the pile shall be made good to the cut-off
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    level, using an approved method so that it will safely withstand the imposed design
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    load.

    2 Lengthening of Reinforced and Prestressed Concrete Piles


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    (a) Any provision for lengthening piles incorporated at the time of manufacture shall be as
    designed or approved.
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    (b) If no provision for lengthening piles was incorporated at the time of manufacture, any
    method for lengthening shall be such that splices are capable of safely resisting the
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    stresses during driving and under service load and shall be subject to approval.
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    3 Driving Repaired or Lengthened Piles

    (a) Repaired or lengthened piles shall not be driven until the added concrete has reached
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    the specified strength of the concrete of the pile.


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    4.1.9 Cutting off pile heads


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    1 Unless otherwise directed by the Engineer, when the driving of a pile has been approved the
    concrete of the head of the pile shall be cut off to the designated level. The length of splice
    reinforcing bars projecting above this level shall be as designated.

    2 Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
    cracked or defective concrete shall be cut away and the pile repaired in an approved manner
    to provide a full and sound section at the cut-off level.

    4.2 PRECAST REINFORCED CONCRETE SEGMENTAL PILES

    4.2.1 Scope

    1 This Part applies to piles made of elements cast at a precasting works away from the site,
    where work cannot normally be closely supervised by the Engineer. The elements are joined
    together as necessary on site during driving using special proven steel joints incorporated
    into the pile elements when cast.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 11
    Part 04: Deep Foundations

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 5, Concrete.
    4.2.2 References

    1 The following Standards are referred to in this Part:


    Eurocode 7, EN1997-1, Section 7 Pile foundation
    BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates
    BS 3100,.....................Steel castings for general engineering purposes
    BS 2789,.....................Spheroidal graphite or nodular graphite cast iron

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    BS 8110,.....................Structural use of concrete.

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    4.2.3 Submittals

    1 The Contractor shall order the piles to suit the construction programme and seek the

    ta
    Engineer's approval before placing the order. When preliminary piles are specified the
    qa
    approval for the piles for the main work will not necessarily be given until the results of the
    driving and tests on preliminary piles have been received and evaluated.
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    4.2.4 Quality Assurance


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    1 A certificate of quality from the pile manufacturer shall be provided to the Engineer when
    required stating that the designated requirements have been fulfilled during manufacture.
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    2 Each pile element shall be marked in such a manner that it can be identified with the records
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    of manufacture, which shall state the date of casting, the cement type, concrete grade,
    element length and any other relevant data. On delivery, the pile elements shall be
    accompanied by records of manufacture.
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    4.2.5 Tolerances in Pile Dimensions


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    1 The cross-sectional dimensions of the pile shall be not less than those designated.
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    2 The head of a pile element or the end of the pile upon which the hammer acts shall be
    square to the pile axis within a tolerance of 1 in 50.

    3 Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The
    centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.

    4 Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m
    long joining two points on that face, nor shall the centre of area of the pile at any cross-
    section along its length deviate by more than 1/500 of the pile length from a line joining the
    centres of area at the ends of the element. Where a pile element is less than 3 m long the
    permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in
    accordance with actual length.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 12
    Part 04: Deep Foundations

    4.2.6 Handling, Transportation, Storage and Acceptance of Piles

    1 The method and sequence of lifting, handling, transporting and storing piles shall be such as
    to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting
    and support points shall be used. During transport and storage, piles shall be appropriately
    supported under the marked lifting points or fully supported along their length.

    2 All pile elements within a stack shall be in groups of the same length. Packing of uniform
    thickness shall be provided between piles at the lifting points.

    3 Concrete shall at no time be subjected to loading, including its own weight, which will induce
    a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the
    specified strength, whichever is the less. For this purpose the assessment of the strength of
    the concrete and of the stresses produced by the loads shall be subject to the approval of the
    Engineer.

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    4 A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm.

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    The measurement shall be made with the pile in its working attitude.

    4.2.7 Materials and components

    1 Fabricated Steel Components ta


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    (a) In the manufacture of jointed precast concrete segmental piles, fabricated steel
    components shall comply with BS 7613 grades 43A or 50A, cast steel components
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    with BS 3100 grade A, and ductile iron components with BS 2789.


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    2 Pile Splices
    er

    (a) The splice joints shall be close-fitting face to face and the locking method shall be
    such as to hold the faces in intimate contact. The design and manufacture of the
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    splicing system shall be approved by the Engineer prior to the commencement of the
    Contract.
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    (b) A spliced pile shall be capable of withstanding the same driving stresses or service
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    axial loads, moments and shear stresses as a single unspliced pile of the same cross-
    et

    sectional dimensions and materials.


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    (c) The welding of a joint to main reinforcement in lieu of a lapped connection with
    projecting bars affixed to the joint will not be permitted.

    3 Pile Toes

    (a) Pile toes shall be constructed so as to ensure that damage is not caused to the pile
    during installation. Where fixity is required or socketing into rock, or in other
    circumstances, an approved shoe may be required.

    4 Pile Head Reinforcement

    (a) Where the pile head is not furnished with a joint, it shall be so reinforced or banded as
    to prevent bursting of the pile under driving conditions.

    5 Main Reinforcement

    (a) The main longitudinal reinforcing bars shall be in one continuous length. Splicing of
    bars will not be permitted except at element ends.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 13
    Part 04: Deep Foundations

    (b) Concrete cover to steel reinforcement shall be in accordance with the requirements of
    BS 8110.
    (c) In very aggressive ground or exposure conditions, cover greater than 25 mm may be
    required, but alternative protection methods may be approved.

    6 Formwork

    (a) If a pile is constructed with a shaped point or shoe, then the end of the pile shall be
    symmetrical about the longitudinal axis of the pile.
    (b) Holes for handling or pitching, where provided in the pile, shall be lined with steel
    tubes; alternatively, approved inserts may be cast in.
    (c) Formwork shall be robust, clean and so constructed as to prevent loss of grout or
    aggregate from the wet concrete and ensure the production of uniform pile sections.
    The piles are to be removed from the formwork carefully so as to prevent damage.

    l .
    .l.
    4.2.8 Driving piles

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    1 Strength of Piles

    (a)
    ta
    Piles shall not be driven until the concrete has achieved the specified characteristic
    strength.
    qa
    2 Leaders and Trestles
    as

    (a) At all stages during driving and until incorporation into the substructure, the pile shall
    be adequately supported and restrained by means of leaders, trestles, temporary
    se

    supports or other guide arrangements to maintain position and alignment and to


    prevent buckling. These arrangements shall be such that damage to the pile does not
    er

    occur.

    3 Performance of Driving Equipment


    ov

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    o

    energy of the driving equipment. Where required in the particular specification,


    dynamic evaluation and analysis shall be provided.
    it
    et

    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile at the moment of driving unless otherwise approved by the Engineer. For
    m

    other types of hammer, the energy delivered to the pile per blow shall be at least
    equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be
    used from floating craft in such a manner as to cause instability of the craft or damage
    to the pile.

    4 Length of Piles

    (a) The length of pile supplied to be driven in any location and any additional lengths to be
    added during driving shall he approved prior to the commencement of pile-driving.
    During the execution of the Works, any changes to the supplied lengths shall be
    approved.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 14
    Part 04: Deep Foundations

    5 Driving Procedure and Redrive Checks

    (a) Except when making field splices, the driving of each pile shall he continuous until the
    specified depth or resistance (set), or both, has been reached. In the event of
    unavoidable interruption to driving, the pile will be accepted provided it can
    subsequently be driven to the specified depth or resistance (set), or both, without
    damage. A follower shall only be used when approved, in which case the Engineer will
    require the set where applicable to be revised in order to take into account reduction in
    the effectiveness of the hammer blow.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    driving characteristics is noted. A detailed record of the driving resistance over the full
    length of the nearest available pile shall be taken if required.
    (c) At the start of the work in a new area or section a detailed driving record shall be made
    over the full length of the first pile and during the last 3 m of subsequent piles until

    l .
    consistency of behaviour is established. Where required, detailed driving records shall

    .l.
    also be made for 5 % of the piles driven, the positions of such piles being specified by

    rw
    the Engineer.
    (d) The Contractor shall give adequate notice and provide all necessary facilities to enable

    ta
    the Engineer to check driving resistance. A set or resistance measurement shall be
    taken only in the presence of the Engineer unless otherwise approved.
    qa
    (e) Redrive checks, if required, shall be carried out to an approved procedure.

    6 Final Set
    as

    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
    se

    penetration in millimetres per ten blows or as the number of blows required to produce
    a penetration of 25 mm.
    er

    (b) When a final set is being measured, the following requirements shall be met:
    ov

    (i) The exposed part of the pile shall be in good condition, without damage or
    distortion.
    o

    (ii) The helmet, dolly and any packing shall be in sound condition.
    it

    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    et

    be flat and at right angles to the pile and hammer axis.


    m

    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded if required.

    7 Preboring

    (a) If preboring is specified, the diameter and depth of prebore shall be as designated.

    8 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.

    4.2.9 Risen Piles

    (a) Piles shall be driven in an approved sequence to minimise the detrimental effects of
    heave and lateral displacement of the ground.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 15
    Part 04: Deep Foundations

    (b) When required, levels and measurements shall be taken to determine the movement
    of the ground or of any pile resulting from the driving process.
    (c) When a pile has risen as a result of adjacent piles being driven, the Engineer may call
    for redriving or other testing to demonstrate that the performance of the pile is
    unimpaired. If required, the Contractor shall make proposals for correcting piles
    detrimentally affected and for avoidance or control of heave effects in subsequent
    work.

    4.2.10 Repair and lengthening of piles

    1 Repair of Damaged Pile Heads

    (a) If it is necessary to repair the head of a pile during driving, the Contractor shall carry
    out such repair in an approved way which allows the driving of the pile to be completed
    without further damage. If the driving of a pile has been accepted but sound concrete

    l .
    of the pile is below the required cut-off level, the pile shall be made good to the cut-off

    .l.
    level, using an approved method so that it will safely withstand the imposed design

    rw
    load.

    2 Lengthening of Piles

    (a) ta
    Where piles are required to be driven to depths exceeding those expected, leaving
    qa
    insufficient projection for bonding into the following works, the piles shall be extended
    or replaced as required by the Engineer using approved materials and methods.
    as

    4.2.11 Cutting off pile heads


    se

    1 Unless otherwise specified, when the driving of a pile has been approved the concrete of the
    head of the pile shall be cut off to the designated level. The length of splice reinforcing bars
    er

    projecting above this level shall be as designated.


    ov

    2 Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
    cracked or defective concrete shall be cut away and the pile repaired in an approved manner
    to provide a full and sound section at the cut-off level.
    it o

    4.3 BORED CAST IN PLACE PILES


    et
    m

    4.3.1 Scope

    1 This Part applies to bored piles in which the pile bore is excavated by rotary or percussive
    means, or both, using short augers, buckets, grabs or other boring tools to advance the open
    bore. Where the open bore is unstable, temporary or permanent casing or bentonite
    suspension may be used to support the wall of the bore prior to concreting.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation


    Section 5, Concrete
    QCS 2014 Section 04: Foundations and Retaining Structures Page 16
    Part 04: Deep Foundations

    4.3.2 References

    1 The following codes of practice are referred to in this Part:


    BS 5573,.....................Code of practice for safety precautions in the construction of large
    diameter boreholes for piling and other purposes
    BS 5930,.....................Code of practice for site investigation.

    4.3.3 Quality Assurance

    1 Inspection

    (a) Each pile bore which does not contain standing water or drilling fluid shall be inspected
    directly or indirectly prior to concrete being placed in it. This inspection shall be carried
    out from the ground surface in the case of piles of less than 750 mm diameter.

    .
    Torches or other approved means of lighting, measuring tapes, and a means of

    l
    .l.
    measuring verticality shall be provided. For piles of 750 mm diameter or larger,
    equipment shall be provided, by the Contractor to enable his representatives and the

    rw
    Engineer to descend into the bore for the purpose of inspection. Any method of
    descent and the equipment used shall comply with the requirements of BS 5573.

    2 Cleanliness of pile bases


    ta
    qa
    (a) On completion of boring and where inspection of a dry pile bore indicates the
    necessity, loose, disturbed or softened soil shall be removed from the bore. Where
    as

    pile bores contain water or drilling fluid, a cleaning process shall be employed before
    concrete is placed. Large debris and accumulated sediment shall be removed using
    appropriate approved methods, which shall be designed to clean while at the same
    se

    time minimising ground disturbance below the pile bases. Water or drilling fluid shall
    be maintained at such levels throughout and following the cleaning operation that
    er

    stability of the bore is preserved.


    ov

    3 Samples and Testing

    (a) If required in the Contract, soil, rock or groundwater samples shall be taken or soil
    o

    tests carried out in-situ while the pile is being bored. The samples shall be taken to an
    it

    approved laboratory for testing as specified.


    et

    (b) The taking of samples and all subsequent handling, transporting and testing shall be
    m

    carried out in accordance with Section 3, Ground Investigation.

    4.3.4 Materials

    1 Permanent Casings

    (a) Permanent casings shall be as specified.

    2 Drilling Fluid Supply

    (a) A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
    powder showing the properties of each consignment delivered to the Site. This
    certificate shall be made available to the Engineer on request. The properties to be
    given by the manufacturer are the apparent viscosity range (in Pascal seconds) and
    the gel strength range (in Pascal) for solids in water.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 17
    Part 04: Deep Foundations

    3 Drilling Fluid Mixing

    (a) Bentonite shall be mixed thoroughly with clean fresh water to make a suspension
    which will maintain the stability of the pile bore for the period necessary to place
    concrete and complete construction. The temperature of the water used in mixing the
    bentonite suspension, and of the suspension when supplied to the borehole, shall be
    not lower than 5 C.
    (b) Where saline or chemically contaminated groundwater occurs, special precautions
    shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh
    water so as to render it suitable in all respects for the construction of piles.

    4 Drilling Fluid Tests

    (a) The frequency of testing drilling fluid and the method and procedure of sampling shall
    be proposed by the Contractor for approval prior to the commencement of the work.
    The frequency may subsequently be varied as required, depending on the consistency
    of the results obtained, subject to approval.

    l .
    .l.
    (b) Control tests shall be carried out on the bentonite suspension, using suitable
    apparatus. The density of freshly mixed bentonite suspension shall be measured daily

    rw
    as a check on the quality of the suspension being formed. The measuring device shall
    be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear
    strength and pH value shall be applied to bentonite supplied to the pile bore. For

    ta
    average soil conditions the results shall generally be within the ranges in Table 4.2.
    qa
    Table 4.2.Tests on Bentonite
    Property to be measured Range of results at 20 C Test method
    as

    Density Less than 1.10 g/ml Mud density balance


    se

    30 - 90 s Marsh cone method


    Viscosity or
    er

    less than 0.020 Pa s Fann viscometer*


    ov

    1.4-10 Pa Shear meter


    Shear strength
    Or
    (10 minute gel strength)
    4-40 Pa Fann viscometer
    o

    pH indicator paper strips


    pH 9.5 - 12
    it

    or electrical pH meter
    et

    * Where the Fann viscometer is specified, the fluid sample should be screened by a
    number 52 sieve (300 m) prior to testing.
    m

    (c) The tests shall be carried out until a consistent working pattern has been established
    account being taken of the mixing process, any blending of freshly mixed bentonite
    suspension and previously used bentonite suspension, and any process which may be
    used to remove impurities from previously used bentonite suspension. When the
    results show consistent behaviour, the tests for shear strength and pH value may be
    discontinued, and tests to determine density and viscosity shall be carried out as
    agreed with the Engineer. In the event of a change in the established working pattern,
    tests for shear strength and pH value shall be reintroduced for a period if required.

    4.3.5 Boring

    1 Boring Near Recently Cast Piles

    (a) Piles shall not be bored so close to other recently completed piles as to damage them.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 18
    Part 04: Deep Foundations

    2 Temporary Casings

    (a) Temporary casing of approved quality or an approved alternative method shall be used
    to maintain the stability of a pile bore which might otherwise collapse.
    (b) Temporary casings shall be free from significant distortion. They shall be of uniform
    cross-section throughout each continuous length. During concreting they shall be free
    from internal projections and encrusted concrete which might adversely affect the
    proper formation of piles.
    (c) The use of a vibrator to insert and withdraw temporary casing may be permitted by the
    Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent
    Structures of this section and to the method not causing disturbance of the ground
    which would adversely affect the construction or the capacity of piles.
    (d) Where piles are bored under water or bentonite suspension in an unlined state, the

    .
    insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing

    l
    .l.
    concrete will not be permitted.

    rw
    (e) Where permanent casing is specified to ensure the integrity of a pile, the Contractor
    shall submit for approval his proposals regarding the method of installation.

    3 Stability of Pile
    ta
    qa
    (a) Where boring takes place through unstable water-bearing strata, the process of
    excavation and the depth of temporary casing employed shall be such that soil from
    outside the area of the pile is not drawn into the pile section and cavities are not
    as

    created outside the temporary casing as it is advanced.


    (b) Where the use of drilling fluid is specified or approved for maintaining the stability of a
    se

    bore, an adequate temporary casing shall be used in conjunction with the method so
    as to ensure stability of the strata near ground level until concrete has been placed.
    er

    During construction the level of drilling fluid in the pile excavation shall be maintained
    ov

    within the cased or stable bore so that it is not less than 1.0 m above the level of
    external standing groundwater at all times.
    o

    (c) In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be
    backfilled without delay and the instructions of the Engineer shall be obtained before
    it

    boring at that location is resumed.


    et
    m

    4 Spillage and Disposal of Drilling Fluid

    (a) All reasonable steps shall be taken to prevent the spillage of bentonite suspension on
    the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be
    removed from the Site without undue delay. Any disposal of bentonite shall comply
    with the regulations of the local controlling authority.

    5 Pumping from Pile Bores

    (a) Pumping from pile bores shall not be permitted unless the bore has been sealed
    against further water entry by casing or unless the soil is stable and will allow pumping
    to take place without ground disturbance below or around the pile.

    6 Continuity of Construction

    (a) For a pile constructed in a stable cohesive soil without the use of temporary casing or
    other form of support, the pile shall be bored and the concrete shall be placed without
    such delay as would lead to significant impairment of the soil strength.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 19
    Part 04: Deep Foundations

    7 Enlarged Pile Bases

    (a) A mechanically formed enlarged base shall be no smaller than the dimensions
    specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the
    shaft diameter. The sloping surface of the frustum forming the enlargement shall make
    an angle to the axis of the pile of not more than 35 .

    4.3.6 Extraction of casing

    1 Workability of Concrete

    (a) Temporary casings shall be extracted while the concrete within them remains
    sufficiently workable to ensure that the concrete is not lifted. During extraction the
    motion of the casing shall be maintained in an axial direction relative to the pile.

    2 Concrete Level

    l .
    .l.
    (a) When the casing is being extracted, a sufficient quantity of concrete shall be

    rw
    maintained within it to ensure that pressure from external water, drilling fluid or soil is
    exceeded and that the pile is neither reduced in section nor contaminated.
    (b) The concrete level within a temporary casing shall be topped up where necessary
    ta
    during the course of casing extraction in such a way that the base of the casing is
    qa
    always below the concrete surface until the casting of the pile has been completed.
    (c) Adequate precautions shall be taken in all cases where excess heads of water or
    as

    drilling fluid could occur as the casing is withdrawn because of the displacement of
    water or fluid by the concrete as it flows into its final position against the walls of the
    pile bore. Where two or more discontinuous lengths of casing (double casing) are
    se

    used in the construction the proposed method of working shall be approved.


    er

    3 Pile Head Casting Level Tolerances


    ov

    (a) For piles cast in dry bores using temporary casing and without the use of a permanent
    lining, pile heads shall be cast to a level above the specified cut-off so that, after
    trimming, a sound concrete connection with the pile can be made. The casting level
    o

    shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be
    it

    above the original ground level. No pile shall be cast with its head below standing
    et

    water level unless approved measures are taken to prevent inflow of water causing
    m

    segregation of the concrete as temporary casing is extracted, and, where approved by


    the Engineer, the groundwater level for each pile shall be treated as the cut-off level for
    the purpose of calculating tolerance.
    (b) For piles cast in dry bores within permanent lining tubes or permanent casings, or
    where their cut-off levels are in stable ground below the base of any casing used, pile
    heads shall be cast to a level above the specified cut-off so that, after trimming, a
    sound concrete connection with the pile can be made. The casting level shall be within
    the tolerance above the cut-off level shown in Table 4.4, but shall not be above the
    original ground level.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 20
    Part 04: Deep Foundations

    (c) For piles cast under water or drilling fluid, the pile heads shall be cast to a level above
    the specified cut-off so that, after trimming to remove all debris and contaminated
    concrete, a sound concrete connection with the pile can be made. The casting level
    shall be within the tolerance above the cut-off level shown in Table 4.4, but shall not be
    above the commencing surface level. Cut-off levels may be specified below the
    standing groundwater level, and where this condition applies the borehole fluid level
    shall not be reduced below the standing groundwater level until the concrete has set.
    (d) Where the cut-off level of piles lies at depths greater than 10 m below the original
    ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after
    discussion with the Contractor and before the commencement of the piling to take
    account of the special conditions which apply.
    Table 4.3
    Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing

    .
    and Without the Use of a Permanent Lining

    l
    .l.
    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m

    rw
    H, m
    0.3 + H/12 + C/8
    where C = length of temporary casing
    0.15-10.00
    ta below the commencing surface*
    qa
    * If H is greater than C, then this tolerance is no longer applicable and the tolerances in
    Table 4.4 will apply.
    as

    Table 4.4
    Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining
    se

    Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the
    Base of Any Casing Used
    er
    ov

    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m
    H, m
    o

    0.15-10.00 0.3 + H/10


    it

    Table 4.5
    et

    Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid**
    m

    Cut-off distance below commencing surface, Casting tolerance above cut-off level, m
    H, m

    1.0 + H /12 + C/8


    0.15-10.00 where C = length of temporary casing
    below the commencing surface

    ** In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
    tolerance is given by deletion of the casing term C/8 in the table.

    4 Water levels

    (a) During extraction of temporary casings, where circumstances are such that newly
    placed unset concrete is brought into contact with external groundwater, precautions
    shall be taken to ensure that the internal concrete pressure at all levels within the pile
    exceeds the external groundwater pressure.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 21
    Part 04: Deep Foundations

    5 Temporary backfilling above pile casting level

    (a) After each pile has been cast, any empty bore remaining shall be protected and shall
    be carefully backfilled as soon as possible with approved materials.

    6 Disposal of excavated material

    (a) Disposal of excavated material shall be carried out by the Contractor as necessary to
    facilitate the Works and to the satisfaction of the Engineer.

    7 Cutting off pile heads

    (a) When cutting off and trimming piles to the specified cut-off level, the Contractor shall
    take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked
    or defective concrete shall be cut away and the pile repaired in an approved manner to
    provide a full and sound section at the cut-off level

    4.4 BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS

    l .
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    AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER
    STEMS

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    4.4.1 Scope

    1 ta
    This Part applies to bored piles which employ a continuous flight auger for both advancing
    qa
    the bore and maintaining its stability. The spoil-laden auger is not removed from the ground
    until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed
    auger to replace the excavated soil.
    as

    2 Related Sections and Parts are as follows:


    se

    This Section
    er

    Part 1, .............. General Requirements for Piling Works


    ov

    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation.


    o

    Section 5, Concrete
    it
    et

    4.4.2 Materials
    m

    1 Concrete Mix Design and Workability

    (a) Where not otherwise stated in this Part, the concrete shall comply with Section 5. The
    design and workability of concrete to be used in the formation of a pile shall produce a
    mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless
    3
    otherwise approved and a minimum cement content of 340 kg/m . The mix shall be
    designed so that segregation does not occur during the placing process, and bleeding
    of the mix shall be minimised.

    2 Grout Mix Design and Workability

    (a) Mix design of grout shall be subject to approval. Cement, water and aggregates for
    grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm
    nominal size and shall be rounded and evenly graded.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 22
    Part 04: Deep Foundations

    (b) The workability of grout mixes, where used, shall be measured by a suitable and
    approved means. The procedure for monitoring the suitability of grout throughout the
    Works shall be stated in writing to the Engineer before beginning of the Works and
    shall be subject to approval.
    (c) Additives to the grout shall require prior approval of the Engineer.

    3 Reinforcement

    (a) All reinforcement shall be placed with the minimum delay after the completion of the
    concreting or grouting operation. It shall be designed and fabricated in cages to permit
    it to be placed in the correct position and to the depth specified through the concrete or
    grout of the pile. Suitable approved spacers shall be provided to maintain the specified
    concrete or grout cover to steel.
    (b) The transverse reinforcement of any reinforcing cage shall be approved and may

    .
    consist of either spirals, hoops or links.

    l
    .l.
    (c) Longitudinal main steel reinforcement shall be continuous over the specified length.

    rw
    Where splices are necessary, the number of laps shall be kept to a minimum and bars
    shall be welded or joined together in an approved manner.
    (d)
    ta
    Reinforcement shall be supported and centred so that it will provide the required
    projection above the cut-off level, and the proper concrete cover.
    qa
    4.4.3 Boring
    as

    1 General
    se

    (a) During uncased boring with continuous flight auger, the feed forward and speed
    (revolutions per minute) are to be adjusted according to the soil conditions in a way
    er

    that the excavation of soil will be limited to a quantity that the lateral support of the
    uncased borehole wall will be ensured.
    ov

    2 Boring Near Recently Cast Piles


    o

    (a) Piles shall not be bored so close to other piles which have recently been cast as to
    it

    damage them.
    et

    3 Removal of Augers from the Ground


    m

    (a) Augers shall not be extracted from the ground during the boring or construction of a
    pile in such a way that an open unsupported bore or inflow of water into the pile section
    would result. While withdrawing the continuous flight auger, the auger shall be rotated
    in the same direction as during drilling into the soil or shall be withdrawn without
    rotation.

    4 Depth of Piles

    (a) Any failure of a pile to reach the designated depth shall be reported to the Engineer
    without delay and a full statement of the reasons given.

    5 Suitability of Boring Equipment

    (a) The piles shall be bored using approved and suitable equipment capable of
    penetrating the ground without drawing surrounding soils laterally into the pile bore.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 23
    Part 04: Deep Foundations

    4.4.4 Placing of concrete or grout

    1 Equipment for Supply of Concrete or Grout to Piles

    (a) Grout or concrete shall be supplied to the pile through suitable tubing and the hollow
    auger stem. All pipe fitments and connections shall be so constructed that grout does
    not leak during the injection process.

    2 Commencement of Concrete or Grout Supply to Each Pile

    (a) The base of the auger stem shall be fitted with a suitable means of sealing it against
    ingress of water and soil until concrete or grout placing begins.
    (b) At the beginning of concrete or grout placement this sealing device shall be removed
    by the application of concrete or grout pressure. Care shall be taken to ensure that the
    auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water
    inflow and soil movement at the base of the auger are minimised. The technique and

    .
    equipment used to initiate and maintain the concrete or grout flow shall be such that a

    l
    .l.
    pile of the full specified cross-section is obtained from the maximum depth of boring to
    the final pile cut-off level.

    rw
    3 Rate of Supply of Concrete or Grout

    (a) The concrete or grout shall be supplied to the pile at a sufficient rate during auger
    ta
    withdrawal to ensure that a continuous monolithic shaft of the full specified cross-
    qa
    section is formed, free from debris or any segregated concrete or grout.
    (b) The rate of withdrawal of the auger, the injection pressures and the rate of supply of
    concrete or grout shall be measured and recorded throughout the phase of auger
    as

    withdrawal for each pile.


    (c) The Contractor shall submit proposals for his method of monitoring construction for
    se

    approval before beginning the Works.


    er

    4 Completion of Piles

    (a) If the concrete or grout placing in any pile cannot be completed in the normal manner,
    ov

    then the pile shall be rebored before concrete has hardened and shall be completely
    replaced.
    o

    5 Casting Level of Pile Head


    it
    et

    (a) Concrete or grout shall be cast to the original ground level in all cases, and the
    reinforcing cage set, as appropriate.
    m

    4.4.5 Cutting off pile heads

    1 When cutting off and trimming piles to the specified cut-off level, the Contractor shall take
    care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or
    contaminated, cracked or defective concrete shall be cut away and the pile repaired in an
    approved manner to provide a full and sound section up to the cut-off level.

    4.5 DRIVEN CAST IN PLACES PILES

    4.5.1 Scope

    1 This Part applies to piles for which a permanent casing of steel or concrete is driven,
    reinforcement placed within it if required, and the casing filled with concrete. It also applies to
    piles in which a temporary casing is driven, reinforcement placed within it and the pile formed
    in the ground by filling the temporary casing with concrete before and during its extraction.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 24
    Part 04: Deep Foundations

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 5, Concrete
    Section 3, Ground Investigation.
    4.5.2 Submittals

    1 Where the Contractor wishes to form a pile with an enlarged base, details of the proposed
    method of forming the base and the materials to be used shall be submitted at the time of
    tendering.

    4.5.3 Quality Assurance

    l .
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    1 Before placing concrete in a pile casing, the Contractor shall check in an approved manner

    rw
    that the casing is undamaged, and free from water or other foreign matter. In the event of
    water or foreign matter having entered the pile casing, either the casing shall be withdrawn,
    repaired if necessary and re-driven, or other action shall be taken as may be approved to
    continue the construction of the pile.
    ta
    qa
    4.5.4 Materials
    as

    1 Permanent Casings

    (a) Permanent casings shall be as specified. Where a permanent casing is to be made


    se

    from a series of short sections it shall be designed and placed so as to produce a


    continuous water-free shaft. The dimensions and quality of the casing shall be
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    adequate to withstand the stresses caused by handling and driving without damage or
    distortion.
    ov

    2 Temporary Casings
    o

    (a) Temporary casings shall be free from significant distortion. They shall be of uniform
    it

    external cross-section throughout each continuous length. During concreting they


    et

    shall be free from internal projections and encrusted concrete which might prevent the
    m

    proper formation of piles.

    3 Pile Shoes

    (a) Pile shoes shall be manufactured from durable material capable of withstanding the
    stresses caused by driving without damage, and shall be designed to give a watertight
    joint during construction.

    4 Reinforcement

    (a) This type of pile shall normally be reinforced over its full length unless permanently
    cased. The use of shorter reinforcement in piles which are not permanently cased
    shall be subject to the approval of the Engineer.
    (b) The number of splices in longitudinal steel bars shall be kept to a minimum. The full
    strength of each bar shall be effective across each splice, which shall be made so that
    there is no detrimental displacement of the reinforcement during the construction of
    the pile.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 25
    Part 04: Deep Foundations

    4.5.5 Driving piles

    1 Piling Near Recently Cast Piles

    (a) Casings shall not be driven or piles formed so close to other piles which have recently
    been cast as to damage them.

    2 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment
    (b) Drop hammers shall not be used from floating craft in such a manner as to cause
    instability of the craft.

    3 Length of Piles

    l .
    (a) The length of pile to be driven in any location shall be approved.

    .l.
    rw
    4 Driving Procedure

    (a) Each pile casing shall be driven continuously until the specified or approved depth or

    ta
    resistance (set), or both, has been reached. In the event of unavoidable interruption to
    driving, the pile will be accepted provided on resumption the casing can be driven to
    qa
    the specified depth or resistance (set), or both, without damage.
    (b) The Contractor shall inform the Engineer without delay if an unexpected change in
    as

    driving characteristics is encountered. A detailed record of the driving resistance over


    the full length of the nearest available subsequent pile shall be taken if required.
    se

    (c) At the start of the work in a new area or section a detailed driving record shall be made
    over the full length of the first pile to be installed and over the last 3 m of the driving of
    er

    subsequent piles until consistency of behaviour is established. Where required,


    detailed driving records shall also be made for 5 % of the piles driven, the positions of
    ov

    such piles being specified by the Engineer.


    (d) The Contractor shall give adequate notice and provide all facilities to enable the
    o

    Engineer to check driving resistance. A set shall be taken only in the presence of the
    it

    Engineer unless otherwise approved.


    et

    5 Final Set
    m

    (a) Where piles are driven to a set, the final set of each pile, pile shell or casing shall be
    recorded either as the penetration in millimetres per ten blows or as the number of
    blows required to produce a penetration of 25 mm.
    (b) When a final set is being measured, the following requirements shall be met:
    (i) The exposed part of the pile casing shall be in good condition, without damage
    or distortion.
    (ii) The dolly, helmet and packing, if any, shall be in sound condition.
    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    be flat and at right angles to the pile and hammer axis.
    (iv) The hammer shall be in good condition, delivering adequate energy per blow,
    and operating correctly.
    (v) Temporary compression of the pile casing shall be recorded if required.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 26
    Part 04: Deep Foundations

    6 Preboring

    (a) If preboring is specified the pile casing shall be pitched after preboring to the
    designated depth and diameter.

    7 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved by the Engineer

    8 Internal Drop Hammer

    (a) Where a casing for a pile without an enlarged base is to be driven by an internal drop
    hammer, a plug consisting of concrete grade 20 with a water/cement ratio not
    exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of
    not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to

    .
    ensure that this height of driving plug is maintained in the casing throughout the period

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    of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of

    rw
    normal driving or after 45 min of hard driving, or, should the driving of a pile be
    interrupted for 30 min or longer, fresh concrete shall be added prior to driving being
    resumed.

    4.5.6 Risen Piles ta


    qa
    1 Piles shall be driven in an approved sequence to minimise any detrimental effects of heave
    and lateral displacement of the ground.
    as

    2 When required, levels and measurements shall be taken to determine the movement of the
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    ground or any pile resulting from the driving process.


    er

    3 When a pile has risen with detrimental effects as a result of adjacent piles being driven the
    Contractor shall, if required, submit to the Engineer his proposals for correcting or
    ov

    compensating for this and for avoidance or control of heave effects in subsequent work.
    o

    4.5.7 Extraction of casing


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    1 Workability of Concrete
    et
    m

    (a) Temporary casings shall be extracted while the concrete within them remains
    sufficiently workable to ensure that the concrete is not lifted.

    2 Concrete Level

    (a) When the casing is being extracted, a sufficient quantity of concrete shall be
    maintained within it to ensure that pressure from external water or soil is exceeded and
    that the pile is neither reduced in section nor contaminated.
    (b) Concrete shall be topped up as necessary while the casing is extracted until the
    required head of concrete to complete the pile in a sound and proper manner has been
    provided. No concrete is to be placed once the bottom of the casing has been lifted
    above the top of the concrete.

    3 Vibrating Extractors

    (a) The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and
    Disturbance) and (Damage to Adjacent Structures).
    QCS 2014 Section 04: Foundations and Retaining Structures Page 27
    Part 04: Deep Foundations

    4 Concrete Casting Tolerances

    (a) For piles constructed without the use of a rigid permanent lining, pile concrete shall be
    cast to the original ground level.
    (b) Where piles are constructed inside rigid permanent lining tubes or permanent casings,
    pile heads shall be cast to a level above the specified cut-off so that, after trimming, a
    sound concrete connection with the pile can be made. In this case, the tolerance of
    casting above the cut-off level shall be determined according to Table 4.6.

    Table 4.6

    Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining
    Tubes or Permanent Casings

    Cut-off distance below original Casting tolerance above cut-off level

    l .
    ground, H, (m) (m)

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    rw
    0.15 to any depth 2.2 + H/10

    5
    ta
    Repair of damaged pile heads and making-up of piles to the correct level
    qa
    (a) When repairing or extending the head of a pile, the head shall be cut off square in
    sound concrete, and all loose particles shall be removed by wire brushing, followed by
    washing with water.
    as

    (b) If the driving of a pile has been accepted but sound concrete of the pile is below the
    se

    cut-off level, the pile shall be made good to the cut-off level with concrete of a grade
    not inferior to that of the concrete of the pile.
    er

    6 Lengthening of cast-in- place piles after driving


    ov

    (a) When it is required to extend a cast-in-place driven pile above ground, the materials to
    be used and procedures to be adopted shall be subject to the approval of the
    o

    Engineer.
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    7 Lengthening of permanent pile casings during construction


    et

    (a) The lengthening of permanent steel pile casings by adding an additional length of the
    m

    same steel casing during construction shall be carried out in accordance with the
    relevant clauses of this Section or by other approved methods. The use of casing
    extension materials and methods other than those specified shall be subject to
    approval.

    8 Temporary backfilling above pile casting level

    (a) After each pile has been cast, any hole remaining shall be protected and shall be
    carefully backfilled as soon as possible with approved materials.

    9 Cutting off pile heads

    (a) When cutting off and trimming piles to the specified cut-off level, the Contractor shall
    take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked
    or defective concrete shall be cut away and the pile repaired in an approved manner to
    provide a full and sound section to the cut-off level.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 28
    Part 04: Deep Foundations

    4.6 STEEL PILES

    4.6.1 Scope

    1 This Part applies to driven steel piles designed to act as bearing piles.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling

    Section 3, Ground Investigation.


    Section 5, Concrete

    . l
    4.6.2 References

    .l.
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    1 The following standards and other documents are referred to in this Part:
    BS 4, ..........................Structural steel sections

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    BS 3100, ....................Steel casting for general engineering purposes.
    BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels
    qa
    BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel
    BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates
    as

    API 5L,........................Interpretation of non-destructive testing.


    se

    4.6.3 Submittals
    er

    1 Where coatings are specified, the Contractor shall submit for approval full details of the
    coating procedure and surface preparation according to relevant British or Swedish
    ov

    Standards.
    o

    4.6.4 Quality Assurance


    it
    et

    1 The Contractor shall provide the Engineer with Works test certificates, analyses, and mill
    sheets, together with a tube manufacturer's certificate showing details of the pile number,
    m

    cast number of the steel and a record of all tests and inspections carried out. The Engineer
    has the right to inspect any stage of the manufacturing processes and shall be given
    adequate notice by the Contractor of such processes and production tests, provided that,
    once he has been notified, any delay in his attendance does not cause delay to, or disrupt,
    the manufacturing process. The Contractor shall provide the Engineer with samples for
    independent testing when requested.

    2 The Contractor shall submit for approval full details of the welding procedures and
    electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as
    may be required by the relevant British Standard or as may be required by the Engineer.
    Only welders who are qualified in the approved welding procedure in accordance with the
    tests laid down in the relevant British Standard, or who have a proven record over the
    previous six months, or who have attained a similar standard, shall be employed on the
    Works. Proof of welders' proficiency shall be made available to the Engineer on request.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 29
    Part 04: Deep Foundations

    4.6.5 Delivery, Storage and Handling

    1 The Contractor shall

    (a) Order the piles to suit the construction programme.


    (b) Obtain the Engineer's approval before placing the order.

    2 When preliminary piles are specified, the approval for the piles for the main work will not
    necessarily be given until the results of the driving and tests on preliminary piles have been
    received and evaluated.

    3 Each pile shall be clearly numbered and its length shown near the pile head using white
    paint. In addition, before being driven, each pile shall be graduated at appropriate intervals
    along its length and at intervals of 250 mm along the top 3 m.

    l.
    4 All piles within a stack shall be in groups of the same length and on approved supports. All

    .l.
    operations such as handling, transporting and storing of piles shall be carried out in a manner

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    such that damage to piles and their coatings is minimised.

    4.6.6 Materials

    1 Pile Shoes ta
    qa
    (a) Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded
    fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related
    as

    standards.
    se

    2 Strengthening of Piles
    er

    (a) The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head
    of a pile shall be made using material of the same grade as the pile unless otherwise
    ov

    approved.

    3 Manufacturing Tolerance
    it o

    (a) All piles shall be of the type and cross-sectional dimensions specified. For standard
    et

    rolled sections the dimensional tolerances and weight shall comply with the relevant
    standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified.
    m

    For proprietary sections the dimensional tolerances shall comply with the
    manufacturer's standards. The rolling or manufacturing tolerances for proprietary
    sections shall be such that the actual weight of section does not differ from the
    theoretical weight by more than +4 % or -2 % unless otherwise agreed. The rolling
    or manufacturing tolerances for steel tubular piles shall be such that the actual weight
    of section does not differ from the theoretical weight by more than 5 %.

    4 Straightness of Piles

    (a) For standard rolled sections the deviation from straightness shall be within the
    compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by
    butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall
    length of the pile.
    (b) For proprietary sections made up from rolled sections, and for tubular piles, the
    deviation from straightness on any longitudinal face shall not exceed 1/600 of the
    length of the pile nor 5 mm in any 3 m length.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 30
    Part 04: Deep Foundations

    5 Fabrication of Piles

    (a) For tubular piles where the load will be carried by the wall of the pile, and if the pile will
    be subject to loads that induce reversal of stress during or after construction, the
    external diameter at any section as measured by using a steel tape on the
    circumference shall not differ from the theoretical diameter by more than 1.
    (b) The ends of all tubular piles as manufactured shall be within a tolerance on ovality of
    1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile
    length.
    (c) The root edges or root faces of lengths of piles that are to be shop butt-welded shall
    not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick
    or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of
    unequal wall thickness are to be butt-welded, the thickness of the thinner material shall
    be the criterion.

    l .
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    6 Matching of Pile Lengths

    rw
    (a) Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being
    joined shall, whenever possible, be evenly staggered at the butt. However, if in order
    to obtain a satisfactory match of the ends of piles or to meet specified straightness, the
    ta
    seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.
    qa
    7 Welding
    as

    (a) Welding of H-piles and piles that will be subjected to stress reversal, during or after
    construction, shall be in accordance with BS 5135.
    se

    (b) For a tubular pile where the load will be compressive and non-reversible and will be
    carried by the wall of the pile or by composite action with a concrete core, the welding
    er

    shall be to BS 5135 or BS 6265.


    ov

    8 Coating Piles for Protection against Corrosion

    (a) Where coatings are specified they shall be provided in accordance with the Particular
    o

    Specification. In general, coatings will not be called for where piles are fully in contact
    it

    with undisturbed natural soils or below the standing water table. Cathodic protection
    et

    may be called for when there is a possibility of stray electrical current from the
    supported structure flowing to earth through the piles.
    m

    4.6.7 Acceptance Standards For Welds

    1 Acceptance Standards for Shop Welds

    (a) Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the
    acceptance standard for interpretation of non-destructive testing specified in latest
    edition of API 5L. The maximum projecting height of weld reinforcement shall not
    exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall
    thicknesses greater than 13 mm.
    (b) Longitudinal welds joining the constituent parts of the box or proprietary section shall
    be in accordance with the manufacturer's specification.
    (c) The maximum projecting height of weld reinforcement for circumferential welds in
    tubular piles shall be the same as specified above for longitudinal welds in tubular
    piles.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 31
    Part 04: Deep Foundations

    2 Acceptance Standards for Site Butt Welds

    (a) Welds shall comply with the requirements of the Weld Quality Acceptance Standards
    for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation,
    General Steels Group.

    4.6.8 Acceptability and inspection of coatings

    1 The finished coating shall be generally of smooth and uniform texture and free from sharp
    protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.

    2 Any coat damaged by subsequent processes, or which has deteriorated to an extent such
    that proper adhesion of the coating is in doubt, shall be removed and the surface shall be
    cleaned to the original standard and recoated with the specified number and thicknesses of
    coats.

    l .
    .l.
    3 The completed coating shall be checked for thickness by an approved magnetic thickness
    gauge. Areas where the thickness is less than that specified shall receive approved

    rw
    additional coating.

    4
    ta
    Average measured thickness should be equal to or greater than the specified thickness and
    no single reading should be less than 85 % of the specified thickness. The completed
    qa
    coating shall also be checked for adhesion by the cross-hatching method with lines spaced at
    ten times the thickness of the coating. Adhesion tests should not be carried out prior to
    seven days after coating.
    as

    5 The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved
    se

    shall be sand blasted and recoated. The coating shall be approved before pitching and
    driving of the piles.
    er

    4.6.9 Driving of piles


    ov

    1 Leaders and Trestles


    o

    (a) At all stages during driving and until incorporation in the superstructure, the free length
    it

    of the pile shall be adequately supported and restrained by means of leaders, trestles,
    et

    temporary supports or other guide arrangements to maintain position and alignment


    m

    and to prevent buckling. In marine works, lengths which remain unsupported after
    driving shall be adequately restrained until incorporated into the permanent Works.
    These constraint arrangements shall be such that damage to piles and their coatings is
    minimised.

    2 Performance of Driving Equipment

    (a) The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
    energy of the driving equipment. Where required in the Contract, dynamic evaluation
    and analysis shall be provided.
    (b) Where a drop hammer is used, the mass of the hammer shall be at least half that of
    the pile unless otherwise approved by the Engineer. For other types of hammer the
    energy delivered to the pile per blow shall be at least equivalent to that of a drop
    hammer of the stated mass. Drop hammers shall not be used from floating craft in
    such a manner as to cause instability of the craft.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 32
    Part 04: Deep Foundations

    3 Length of Piles

    (a) The length of pile to be driven and any additional lengths of pile to be added during
    driving shall be approved by the Engineer.

    4 Driving Procedure and Redrive Checks

    (a) The driving of each pile shall be continuous until the specified depth or resistance
    (set), or both, has been reached. In the event of unavoidable interruption to driving,
    the pile will be accepted provided it can be driven to the specified depth or resistance
    (set), or both, without damage.
    (b) A follower shall not be used unless approved, in which case the Engineer will require
    the set where applicable to be revised in order to take into account reduction in the
    effectiveness of the hammer blow.

    .
    (c) The Contractor shall inform the Engineer as soon as an unexpected change in driving

    l
    .l.
    characteristics is noted. A detailed record of the driving resistance over the full length
    of the nearest subsequent pile shall be taken, if required by the Engineer.

    rw
    (d) At the start of the work in a new area or section a detailed record shall be made over
    the full driving length of the first pile, and during the last 3 m of the driving of

    ta
    subsequent piles, to establish the driving behaviour. Where required, detailed driving
    records shall also be made for 5 % of the piles driven, the locations of such piles being
    qa
    specified by the Engineer.
    (e) The Contractor shall give adequate notice and provide all necessary facilities to enable
    as

    the Engineer to check driving resistance. A set or resistance measurement shall be


    taken only in the presence of the Engineer unless otherwise approved.
    se

    (f) Redrive checks, if required, shall be carried out in accordance with an approved
    procedure.
    er

    5 Final Set or Resistance


    ov

    (a) When driving to a set criterion, the final set of each pile shall be recorded either as the
    penetration in millimetres per ten blows or as the number of blows required to produce
    o

    a penetration of 25 mm.
    it
    et

    (b) When a final set or resistance is being measured, the following requirements shall be
    met:
    m

    (i) The exposed part of the pile shall be in good condition, without damage or
    distortion.
    (ii) The dolly and packing, if any, shall be in sound condition.
    (iii) The hammer blow shall be in line with the pile axis and the impact surfaces shall
    be flat and at right angles to the pile and hammer axis.
    (iv) The hammer shall be in good condition, delivering adequate energy per blow
    and operating correctly.
    (v) The temporary compression of the pile shall be recorded, if required by the
    Engineer.

    6 Preboring

    (a) If preboring is specified the pile shall be pitched after preboring to the designated
    depth and diameter.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 33
    Part 04: Deep Foundations

    7 Jetting

    (a) Jetting shall be carried out only when the Contractor's detailed proposals have been
    approved.

    4.6.10 Risen Piles

    1 Piles shall be driven in an approved sequence to minimise any detrimental effects of heave
    and lateral displacement of the ground.

    2 When required by the Engineer, levels and measurements shall be taken to determine the
    movement of the ground or any pile resulting from the driving of adjacent piles.

    3 When a pile has risen as a result of adjacent piles being driven, the Engineer may call for
    redriving or other testing to demonstrate that the performance of the pile under load is

    .
    unimpaired. If required, the Contractor shall make proposals for correcting detrimentally

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    .l.
    affected piles and for avoidance or control of heave in subsequent work.

    rw
    4.6.11 Preparation of pile heads

    1
    ta
    If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within
    5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete
    qa
    they shall be cut to that same tolerance and protective coatings shall be removed from the
    surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.
    as

    4.7 MICROPILES (TO BE ADDED LATER)


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    4.8 REDUCTION OF FRICTION ON PILES


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    4.8.1 Scope
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    1 This Part includes preapplied bituminous or other proprietary friction-reducing coating, pre-
    applied low-friction sleeving, formed-in-place low-friction surround, and preinstalled low-
    o

    friction sleeving.
    it
    et

    2 Related Parts are as follows:


    m

    This Section
    Part 1, .............. General Requirements for Piling Works
    Part 2, .............. Concrete Works for Piling
    Section 3, Ground Investigation.
    4.8.2 Submittals

    1 Where the particular method of reducing friction is not specified, the Contractor shall submit
    full details of the method which he proposes.

    4.8.3 Friction Reducing Methods

    1 General

    (a) Where a means of reducing friction on any specified length of pile is required by the
    Contract, the Contractor shall provide a suitable interface between pile and soil by one
    of the following, or other approved, methods
    QCS 2014 Section 04: Foundations and Retaining Structures Page 34
    Part 04: Deep Foundations

    (i) Preapplied bituminous or other proprietary friction-reducing coating.


    (ii) Preapplied low-friction sleeving.
    (iii) Formed-in-place low-friction surrounds.
    (iv) Preinstalled low-friction sleeving.

    2 Preapplied Bituminous or other Friction-Reducing Coating Materials

    (a) Where a proprietary product is specified, the process of cleaning pile surfaces, and the
    conditions and methods of application shall conform to the manufacturer's current
    instructions. All materials shall conform to the manufacturer's specification, which
    shall be given to the Engineer before any coating is applied.
    (b) Where a friction-reducing material has been applied to a preformed pile prior to
    installation, it shall be protected from damage during handling and transportation. In

    .
    the event of inadvertent damage to the coating, it shall be repaired on site, prior to the

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    .l.
    pile being driven, to the same specification as the original coating. Where bituminous
    materials are involved, precautions shall be taken as necessary in hot weather to

    rw
    prevent excessive flow or displacement of the coating. The coated piles shall be
    adequately protected against direct sunlight and, if stacked, they shall be separated to
    prevent their coatings sticking together.
    ta
    qa
    (c) In the case of applied coatings, the piles shall not be driven when the air temperature
    is such that the coating will crack, flake or otherwise be damaged prior to entry into the
    ground. Where bituminous materials are involved, driving shall be carried out while
    as

    the temperature is at or above 5 C unless otherwise approved or called for in the


    manufacturer's instructions.
    se

    3 Preapplied Low-Friction Sleeving


    er

    (a) Piles may be driven with a preapplied low-friction sleeving subject to the approval of
    the detailed design and method by the Engineer.
    ov

    4 Formed-In-Place Low-Friction Surround


    o

    (a) Where a hole is bored in the ground and filled with low-friction material through which a
    it

    pile is subsequently driven or placed, the method and the properties of the low-friction
    et

    material both above and below standing groundwater level, together with the
    dimensions of the prebored hole in relation to the pile, shall be approved by the
    m

    Engineer.

    5 Preinstalled Low-Friction Sleeving

    (a) Where a system is employed involving placing a low-friction sleeve in the ground prior
    to pile installation, the detailed materials and method of installation of the sleeving shall
    be approved by the Engineer.

    4.8.4 Inspection

    1 The Engineer may call for piles to be partially exposed or extracted at the commencement of
    a contract in order to demonstrate that the method of installation does not impair the
    effectiveness of the system in the circumstances of use on the particular site. Where damage
    is found to have occurred, or is likely to occur in the opinion of the Engineer, additional
    measures or variation of the method may be called for. At the discretion of the Engineer,
    further inspections shall be carried out to ascertain the effectiveness of the additional
    measures.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 35
    Part 04: Deep Foundations

    4.8.5 Driving resistance

    1 Allowance shall be made in driving piles to a required resistance or set for any differences
    between the short-term driving resistance and the long-term static resistance of the coating
    or surrounding low-friction material which is in use.

    4.9 PILE LOAD TESTING

    4.9.1 Static Load Testing of Piles

    1 Scope

    (a) This Part deals with the testing of a pile by the controlled application of an axial load. It
    covers vertical and raking piles tested in compression (i.e. subjected to loads or forces
    in a direction such as would cause the piles to penetrate further into the ground) and

    l .
    vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as

    .l.
    would cause the piles to be extracted from the ground).

    rw
    2 References

    The following standard is referred to in this Part:


    ta
    BS 1881, ....................Methods of testing concrete.
    qa
    3 Submittals
    as

    (a) When required, the design and full details of the proposed load application system
    shall be submitted to the Engineer prior to the commencement of testing. The load
    se

    application system shall be satisfactory for the required test.

    4 Definitions
    er

    (a) Allowable pile capacity: a load which is not less than the specified working load and
    ov

    which takes into account the pile's ultimate bearing capacity, the materials from which
    the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the
    o

    overall bearing capacity of the ground beneath the piles and any other relevant factors.
    it

    The allowable pile capacity indicates the ability of a pile to meet the specified loading
    et

    requirements.
    m

    (b) Compression pile: a pile which is designed to resist compressive (downward) axial
    load.
    (c) Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate
    the soil at a constant controlled speed, while the loads applied at the top of the pile in
    order to maintain the constant rate of penetration are continuously measured. The
    purpose of the test is to derive the ultimate bearing capacity of a pile and not its load
    settlement characteristics.
    (d) Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is
    subject to tension rather than compression. The purpose of the test is to determine
    the 'pull-out' capacity of a pile.
    (e) Design verification load (DVL): a test load, in lieu of a specified working load, applied
    to a single pile at the time of testing to determine that site conditions conform to design
    assumptions. This load will be peculiar to each preliminary (test) pile and should equal
    the maximum specified working load for a pile of the same dimensions and material,
    plus allowances for soil-induced forces and any other particular conditions of the test.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 36
    Part 04: Deep Foundations

    (f) Kentledge: ballast used in a loading test.


    (g) Maintained load test: a loading test in which each increment of load is held constant
    either for a defined period of time or until the rate of settlement falls to a specified
    value.
    (h) Preliminary pile: a test pile installed before the commencement of the main piling
    works or a specific part of the Works for the purpose of establishing the suitability of
    the chosen type of pile and for confirming its design, dimensions and bearing capacity.
    (i) Proof load: a load applied to a selected working pile to confirm that it is suitable for the
    load at the settlement specified. A proof load should not normally exceed the design
    verification load plus 50 % of the specified working load.
    (j) Raking pile: a batter pile, installed at an inclination to the vertical.
    (k) Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a

    .
    resistance against which the pile is tested.

    l
    .l.
    (l) Specified working load (SWL): the designated load on the head of a pile.

    rw
    (m) Tension pile: a pile which is designed to resist a tensile (upward) axial force.
    (n) Test pile: any pile, preliminary or part of the works, to which a test is applied.
    (o) ta
    Ultimate bearing capacity: the load at which the resistance of the soil becomes fully
    qa
    mobilised through friction, end bearing or a combination thereof.
    (p) Working pile: one of the piles forming the foundation of a structure.
    as

    5 Construction of a preliminary pile to be tested


    se

    (a) Notice of Construction


    (i) The Contractor shall give the Engineer at least 48 hours' notice of the
    er

    commencement of construction of any preliminary pile which is to be test-


    ov

    loaded.
    (b) Method of Construction
    o

    (i) Each preliminary test pile shall be constructed in a manner similar to that to be
    it

    used for the construction of the working piles, and by the use of similar
    et

    equipment and materials. Any variation will be permitted only with prior approval.
    m

    (c) Boring or Driving Record


    (i) For each preliminary pile to be tested, a detailed record of the conditions
    experienced during boring and of the progress during driving, shall be made and
    submitted to the Engineer daily, not later than noon on the next working day.
    Where the Engineer requires soil samples to be taken or in-situ tests to be
    made, the Contractor shall include that in the daily report, as well as the test
    results.
    (d) Concrete Test Cubes
    (i) In the case of concrete piles, four test cubes shall be made from the concrete
    3
    used in the manufacturer of each preliminary test pile and from each 50 m of
    the concrete used in the manufacture of working piles. If a concrete pile is
    extended or capped for the purpose of testing, an additional four cubes shall be
    made from the corresponding batch of concrete. The cubes shall be made and
    tested in accordance with BS 1881.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 37
    Part 04: Deep Foundations

    (ii) The pile test shall not be started until the strength of the cubes taken from the
    pile exceeds twice the average direct stress in any pile section under the
    maximum required test load, and the strength of the cubes taken from the cap
    exceeds twice the average stress at any point in the cap under the same load.
    Variation of procedure will be permitted only if approved by the Engineer.
    (e) Preparation of a Working Pile to be Tested
    (i) If a test is required on a working pile the Contractor shall cut off or otherwise
    prepare the pile for testing as required by the Engineer.
    (f) Cut-off Level
    (i) The cut-off level for a preliminary test pile shall be approved by the Engineer.

    6 Supervision

    .
    (a) The setting-up of pile testing equipment shall be carried out under competent

    l
    .l.
    supervision and the equipment shall be checked to ensure that the set-up is
    satisfactory before the commencement of load application.

    rw
    (b) All tests shall be carried out only under the direction of an experienced and competent
    supervisor experienced with the test equipment and test procedure. All personnel

    ta
    operating the test equipment shall have been trained in its use.
    qa
    7 Safety precautions

    (a) General
    as

    (i) Design, erection and dismantling of the pile test reaction system and the
    se

    application of load shall be carried out according to the requirements of the


    various applicable statutory regulations concerned with lifting and handling
    er

    heavy equipment and shall safeguard operators and others who may from time
    to time be in the vicinity of a test from all avoidable hazards.
    ov

    (b) Kentledge
    (i) Where kentledge is used, the Contractor shall construct the foundations for the
    o

    kentledge and any cribwork, beams or other supporting structure in such a


    it

    manner that there will not be differential settlement, bending or deflexion of an


    et

    amount that constitutes a hazard to safety or impairs the efficiency of the


    operation. The kentledge shall be adequately bonded, tied or otherwise held
    m

    together to prevent it becoming unstable because of deflexion of the supports or


    for any other reason.
    (ii) When kentledge constitutes the principal component of a reaction system, its
    weight for each test shall be at least 25% greater than the maximum test load
    for that test. The weight may be determined by scale or the density and volume
    of the constituent materials. In adding kentledge, care shall be taken to properly
    position the centre of gravity of the stack.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 38
    Part 04: Deep Foundations

    (c) Tension Piles, Reaction Piles and Ground Anchorages


    (i) Where tension piles, reaction piles or ground anchorages constitute the principal
    components of a reaction system, they shall be so designed that they will resist
    the forces applied to them safely and without excessive deformation which could
    cause a safety hazard during the work. Such piles (which, unless approved, will
    not be working piles) or anchorages shall be driven in the specified locations,
    and all bars, tendons or links shall be aligned to provide a stable reaction in the
    direction required. Any welding employed to extend or to fix anchorages to a
    reaction frame shall be carried out so that the full strength of the system is
    adequate and unimpaired.
    (d) Testing Equipment
    (i) In all cases the Contractor shall ensure that when the hydraulic jack and load-
    measuring device are mounted on the pile head the whole system will be stable

    .
    up to the maximum load to be applied.

    l
    .l.
    (ii) If in the course of carrying out a test any unforeseen occurrence should take

    rw
    place, further loading shall not be applied until a proper engineering assessment
    of the condition has been made and steps have been taken to rectify any fault.
    Reading of gauges should, however, be continued where possible and if it is
    safe to do so.
    ta
    qa
    (iii) Where an inadequacy in any part of the system might constitute a hazard,
    means shall be provided to enable the test to he controlled from a position
    remote from of the kentledge stack or test frame.
    as

    (iv) The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
    se

    operated under hydraulic pressure shall be capable of withstanding a pressure


    of 1.5 times the maximum pressure used in the test without leaking. The
    er

    maximum test load expressed as a reading on the gauge in use shall be


    displayed and all operators shall be made aware of this limit.
    ov

    (e) Pile Head for Compression Test


    (i) For a pile that is tested in compression, the pile head or cap shall be formed to
    o

    give a plane surface which is normal to the axis of the pile, sufficiently large to
    it

    accommodate the loading and settlement measuring equipment and adequately


    et

    reinforced or protected to prevent damage from the concentrated load applied


    m

    by the loading equipment.


    (ii) Any test pile cap shall be concentric with the test pile; the joint between the cap
    and the pile shall have a strength equivalent to that of the pile.
    (iii) Sufficient clear space shall be made under any part of the cap projecting beyond
    the section of the pile so that, at the maximum expected settlement, load is not
    transmitted to the ground by the cap.
    (f) Pile Connection for Tension Test
    (i) For a pile that is tested in tension, means shall be provided for transmitting the
    test load axially without inducing moment in the pile. The connection between
    the pile and the loading equipment shall be constructed in such a manner as to
    provide strength equal to 1.5 times the maximum load which is to be applied to
    the pile during the test.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 39
    Part 04: Deep Foundations

    8 Reaction systems

    (a) Compression Tests


    (i) The reaction for compression tests shall be provided by kentledge, tension piles
    or specially constructed anchorages. Kentledge shall not be used for tests on
    raking piles except where the test set-up has been specifically designed to
    conform to Item 7(g). and has been approved by the Engineer.
    (ii) Where kentledge is to be used, it shall be supported on cribwork and positioned
    so that the centre of gravity of the load is as close as possible to the axis of the
    pile. The bearing pressure under supporting cribs shall be such as to ensure
    stability of the kentledge stack.
    (b) Tension Tests
    (i) The reaction for tension tests shall be provided by compression piles, rafts or

    l .
    grillages constructed on the ground. In all cases the resultant force of the

    .l.
    reaction system shall be coaxial with the test pile.

    rw
    (ii) Where inclined piles or reactions are proposed, full details shall be submitted for
    approval prior to the commencement of testing.
    (c) Working Piles
    ta
    qa
    (i) Working piles shall not be used as reaction piles without approval from the
    Engineer.
    as

    (ii) Where working piles are used as reaction piles their movement shall be
    measured and recorded to with an accuracy of 0.5 mm, and recorded.
    se

    (d) Spacing
    (i) Where kentledge is used for loading vertical piles in compression, the distance
    er

    from the edge of the test pile to the nearest part of the crib supporting the
    ov

    kentledge stack in contact with the ground shall be not less than 1.3 m.
    (ii) The centre-to-centre spacing of vertical reaction piles from a test pile shall
    conform to Paragraph 1 above, but shall be not less than three times the
    o

    diameter of the test pile or the reaction piles or 2 m, whichever is the greatest,
    it

    except in the case of piles of 300 mm diameter (or equivalent) or less, where the
    et

    distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged


    m

    pile cap, the same criterion shall apply with regard to the pile shaft, with the
    additional requirement that no surface of a reaction pile shall be closer to the
    pile cap of the test pile than one half of the pile cap plan dimension.
    (iii) Where ground anchorages are used to provide a test reaction for loading in
    compression, no section of fixed anchor length transferring load to the ground
    shall be closer to the test pile than three times the diameter of the test pile.
    Where the pile to be tested has an enlarged pile cap, the same criterion shall
    apply with regard to the pile shaft, with the additional requirement that no section
    of the fixed anchor transferring load to the ground shall be closer to the pile cap
    than a distance equal to one half the pile cap plan dimension.
    (e) Adequate Reaction
    (i) The reaction frame support system shall be adequate to transmit the maximum
    test load in a safe manner without excessive movement or influence on the test
    pile. Calculations shall be provided to the Engineer when required to justify the
    design of the reaction system.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 40
    Part 04: Deep Foundations

    (f) Care of Piles


    (i) The method employed in the installation of the reaction system shall be such as
    to prevent damage to any test pile or working pile.

    9 Equipment for applying load

    (a) The equipment used for applying load shall consist of a hydraulic ram or jack. The
    jack shall be arranged in conjunction with the reaction system to deliver an axial load
    to the test pile. Proposals to use more than one ram or jack will be subject to approval
    by the Engineer of the detailed arrangement. The complete system shall be capable of
    safely transferring the maximum load required for the test. The length of stroke of a
    ram shall be sufficient to account for deflexion of the reaction system under load plus a
    deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise
    specified or agreed prior to commencement of test loading.

    l .
    10 Measurement of load

    .l.
    (a) A load measuring device shall be used and in addition a calibrated pressure gauge

    rw
    included in the hydraulic system. Readings of both the load measuring device and the
    pressure gauge shall be recorded. In interpreting the test data the values given by the

    ta
    load measuring device shall normally be used; the pressure gauge readings are
    required as a check for gross error.
    qa
    (b) The load measuring device may consist of a load measuring column, pressure cell or
    other appropriate system. A spherical seating of appropriate size shall he used to
    as

    avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load
    application and measuring system. Load measuring and application devices shall be
    se

    short in axial length in order to secure stability. The Contractor shall ensure that axial
    loading is maintained.
    er

    (c) The load measuring device shall be calibrated before and after each series of tests,
    whenever adjustments are made to the device or at intervals appropriate to the type of
    ov

    equipment. The pressure gauge and hydraulic jack shall be calibrated together.
    Certificates of calibration shall be supplied to the Engineer.
    o

    11 Control of loading
    it
    et

    (a) The loading equipment shall enable the load to be increased or decreased smoothly or
    m

    to be held constant at any required value.

    12 Measuring pile head movement

    (a) Maintained Load Test


    (i) In a maintained load test, movement of the pile head shall he measured by one
    of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one
    of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.
    (b) CRP and CRU Tests
    (i) In a CRP or a CRU test, the method in Item 11 (d) shall be used. Check-
    levelling of the reference frame or the pile head shall not be required. The dial
    gauge shall be graduated in divisions of 0.02 mm or less.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 41
    Part 04: Deep Foundations

    (c) Reference Beams and Dial Gauges


    (i) An independent reference beam or beams shall be set up to enable
    measurement of the movement of the pile to be made to the required accuracy.
    The supports for a beam shall be founded in such a manner and at such a
    distance from the test pile and reaction system that movements of the ground
    do not cause movement of the reference beam or beams which will affect the
    accuracy of the test. The supports of the beam or beams shall be at least three
    test pile diameters or 2 m from the centre of the test pile, whichever distance is
    the greater.
    (ii) Check observations of any movements of the reference beam or beams shall be
    made and a check shall be made of the movement of the pile head relative to a
    remote reference datum at suitable intervals during the progress of the test.
    (iii) The measurement of pile movement shall be made by four dial gauges rigidly

    .
    mounted on the reference beam or beams, bearing on prepared flat surfaces

    l
    .l.
    fixed to the pile cap or head and normal to the pile axis. Alternatively, the
    gauges may be fixed to the pile and bear on prepared surfaces on the reference

    rw
    beam or beams. The dial gauges shall be placed equidistant from the pile axis
    and from each other. The dial gauges shall enable readings to be made to an

    ta
    accuracy of at least 0.1 mm and have a stem travel of at least 25 mm.
    Machined spacer blocks may be used to extend the range of reading. Equivalent
    qa
    electrical displacement-measuring devices may be substituted.
    (d) Optical Levelling Method
    as

    (i) An optical levelling method by reference to a remote datum may be used.


    se

    (ii) Where a level and staff are used, the level and scale of the staff shall be chosen
    to enable readings to be made to within an accuracy of 0.5 mm. A scale
    er

    attached to the pile or pile cap may be used instead of a levelling staff. At least
    two reliable independent datum points shall be established. Each datum point
    ov

    shall be so situated as to permit a single setting-up position of the level for all
    readings.
    o

    (iii) No datum point shall be located where it can be affected by the test loading or
    it

    other operations on the Site.


    et

    (e) Reference Wires and Scales


    m

    (i) Two parallel reference wires, one on either side of the pile, shall be held under
    constant tension at right angles to the test pile axis between supports formed as
    in the method in Item 11 (d). The wires shall be positioned against scales fixed
    to the test pile head in an axial direction and the movements of the scales
    relative to the wires shall be determined.
    (ii) Check observations of any movements of the supports of the wires shall be
    made and a check shall be made on the movement of the pile head at approved
    time intervals. Readings shall be taken to within an accuracy of 0.5 mm.
    (f) Other Methods
    (i) The Contractor may submit for approval any other method of measuring the
    movement of the test pile head.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 42
    Part 04: Deep Foundations

    13 Protection of testing equipment

    (a) Protection from Weather


    (i) Throughout the test period all equipment for measuring load and movement
    shall be protected from exposure to adverse effect of weather.
    (b) Prevention of Disturbance
    (i) Construction activity and persons who are not involved in the testing process
    shall be kept at a sufficient distance from the test to avoid disturbance to the
    measuring apparatus. Full records shall be kept of any intermittent unavoidable
    activity that might affect the test set-up.

    14 Notice of test

    (i) The Contractor shall give the Engineer at least 24 hours' notice of the

    .
    commencement of the test. No load shall be applied to the test pile before the

    l
    .l.
    commencement of the specified test procedure.

    rw
    15 Test procedure

    (a) Proof Load Test Procedure (working compression piles)


    (i) ta
    The maximum load which shall be applied in a proof test shall normally be the
    qa
    sum of the design verification load (DVL) plus 50 % of the specified working load
    (SWL). The loading and unloading shall be carried out in stages as shown in
    Table 4.7. Any particular requirements given in the particular contract
    as

    documentation shall be complied with.


    se

    (ii) Following each application of an increment of load, the load shall be maintained
    at the specified value for not less than the period shown in Table 4.7 and until
    er

    the rate of settlement is less than 0.25 mm/h and decreasing. The rate of
    settlement shall be calculated from the slope of the line obtained by plotting
    ov

    values of settlement versus time and drawing a smooth curve through the
    points.
    o

    (iii) Each decrement of unloading shall proceed after the expiry of the period shown
    it

    in Table 4.7.
    et

    (iv) For any period when the load is constant, time and settlement shall be recorded
    m

    immediately on reaching the load, at not more than 5 min intervals up to 15 min;
    at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and
    4 h; and 1 h intervals between 4 h and 12 h after the application of the increment
    of load.
    (v) Where the methods of measuring pile head movement given in Item 11 is used,
    the periods of time for which loads must be held constant to achieve the
    specified rates of settlement shall be extended as necessary to take into
    account the lower levels of accuracy available from these methods and to allow
    correct assessment of the settlement rate.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 43
    Part 04: Deep Foundations

    Table 4.7
    Load * Minimum time of holding load
    25% DVL 1h
    50% DVL 1h
    75% DVL 1h
    100% DVL 1h
    75% DVL 10 min
    50% DVL 10 min
    25% DVL 10 min
    0 1h
    100% DVL 6h
    100% DVL + 25% SWL 1h
    100% DVL + 50% SWL 6h
    100% DVL + 25% SWL 10 min

    l .
    100% DVL 10 min

    .l.
    75% DVL 10 min

    rw
    50% DVL 10 min
    25% DVL 10 min
    0 1h
    100% DVL
    100% DVL + 50% SWL ta 6h
    6h
    qa
    100% DVL + 75% SWL 1h
    100% DVL + 100% SWL 6h
    100% DVL + 75% SWL 10 min Applicable
    as

    100% DVL + 50% SW 10 min to tests on


    100% DVL + 25% SW 10 min Preliminary
    se

    100% DVL 10 min Pile only


    75% DVL 10 min
    50% DVL 10 min
    er

    25% DVL 10 min


    ov

    0 1h
    * SWL denotes specified working load; DVL denotes design verification load.
    o

    (b) Test Procedure for Preliminary Compression Piles


    it

    (i) The procedure to be adopted for carrying out load tests on preliminary
    et

    compression piles shall be either the extended proof load test procedure or the
    m

    constant rate of penetration testing procedure given below. A normal proof load
    test will constitute the first stage of such a test unless otherwise specified.
    (ii) Extended proof load test procedure. Where test pile is to be loaded up to the
    sum of design verification load (DVL) plus 100 % of the specified working load,
    the loading procedure may be carried out as a continuation of the proof load
    testing procedure given in Item 14 (a).
    (iii) Following the completion of the proof load test, the load shall be restored in two
    stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages
    of 25 % of the specified working load. Following each application of an
    increment of load, the load shall be maintained at the specified value for the
    period shown in Table 4.7 and until the rate of settlement is decreasing and is
    less than 0.25 mm/h.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 44
    Part 04: Deep Foundations

    (iv) Where verification of required minimum factor of safety is called for or the pile is
    to be tested to failure, the loading procedure shall be continued after reaching
    DVL +100 % SWL stage by increasing the load in increments of 25 % of the
    specified working load or other specified amount until the maximum specified
    load of the test is reached. Following each application of increment of load, the
    load shall be maintained at the specified value for not less than 1 h and until the
    rate of settlement is decreasing and is less than 0.25 mm/h, or other approved
    rate appropriate to the stage of loading and its proximity to a failure condition.
    Permissible settlement at the load corresponding to the required minimum factor
    of safety called for in the design will not normally be specified.
    (v) The rate of settlement shall be calculated from the slope of the line obtained by
    plotting values of settlement versus time and drawing a smooth curve through
    the points. Reduction of load at the end of the test shall be gradual as required
    by Item 14 (a).and the final rebound of the pile head shall be recorded.

    l .
    (vi) Constant rate of penetration (CRP) testing procedure. Where it is required to

    .l.
    determine the ultimate load of a preliminary compression pile, and particularly

    rw
    where piles are largely embedded in and bearing on clay soils, the CRP testing
    procedure will normally be specified.
    (vii)
    ta
    The rate of movement of the pile head shall be maintained constant in so far as
    is practicable and shall be approximately 0.01 mm/s.
    qa
    (viii) Readings of loads, penetration and time shall be made simultaneously at regular
    intervals; the interval chosen shall be such that a curve of load versus
    as

    penetration can be plotted without ambiguity.


    (ix) Loading shall be continued until one of the following results is obtained
    se

    1. The maximum required test load.


    er

    2. A constant or reducing load has been recorded for an interval of


    ov

    penetration of 10 mm.
    3. A total movement of the pile base equal to 10 % of the base diameter, or
    any other greater value of movement specified, has been reached.
    it o

    (x) The load shall then be reduced in five approximately equal stages to zero load,
    et

    penetration and load being recorded at each stage.


    m

    (c) Testing of Piles Designed to Carry Load in Tension


    (i) The testing of piles designed to carry load in tension shall follow the same
    procedure as specified in 4.9.1
    (ii) In testing by the constant rate of uplift method, overall movements of the pile
    head will normally be less than those expected in a constant rate of penetration
    test. The rate of movement of the pile head shall be maintained at approximately
    0.005 mm/s in so far as is practicable.

    16 Completion of a test

    (a) Removal of Test Equipment


    QCS 2014 Section 04: Foundations and Retaining Structures Page 45
    Part 04: Deep Foundations

    (i) On completion of a test and subject to the approval of the Engineer, all
    measuring equipment and load application devices shall be dismantled and
    checked. All other test equipment, including kentledge, beams and supporting
    structures shall be removed from the test pile location. Measuring and other
    demountable equipment shall be stored in a safe manner so that it is available
    for further tests, or removed from the Site as approved by the Engineer.
    (ii) Temporary tension piles and ground anchorages shall be cut off below ground
    level, and off-cut materials removed from the Site. The ground shall be restored
    to the original contours.
    (b) Preliminary Test Pile Cap
    (i) Unless otherwise specified, the head of each preliminary test pile shall be cut off
    below ground level, off-cut material shall be removed from the Site and the
    ground restored to the original contours.

    l .
    (c) Proof Test Pile Cap

    .l.
    (i) On completion of a test on a proof pile, the test pile cap shall be prepared as

    rw
    specified and left in a state ready for incorporation into the Permanent Works.
    Any resulting off-cut materials shall be removed from the Site.

    4.9.2 Presentation of results


    ta
    qa
    1 Results to be submitted
    as

    (a) During the progress of a test, all records taken shall be available for inspection by the
    Engineer.
    se

    (b) Results shall be submitted as


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    (i) Preliminary report of the test results to the Engineer, unless otherwise directed,
    within 24 hours of the completion of the test, which shall show.
    ov

    1. For a test by maintained load: for each stage of loading, the period for
    which the load was held, the load and the maximum pile movement at the
    o

    end of the stage.


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    2. For a CRP or CRU test: the maximum load reached and a graph of load
    et

    against penetration or load against uplift.


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    (ii) The final report of recorded data as prescribed in Item 15 (b).within ten days of
    the completion of the test.

    2 Schedule of Recorded Data

    (a) The Contractor shall provide information about the test pile in accordance with the
    following schedule where applicable.
    (i) General.
    1. site location contract identification
    2. proposed structure
    3. main contractor
    4. piling contractor
    5. engineer client/employer
    6. date and time of test
    QCS 2014 Section 04: Foundations and Retaining Structures Page 46
    Part 04: Deep Foundations

    (ii) Pile details.


    1. all types of pile
    2. identification (number and location)
    3. specified working load (SWL)
    4. design verification load (DVL)
    5. original ground level at pile location
    6. head level at which test load was applied
    7. type of pile
    8. vertical or raking, compression or tension
    9. shape and size of cross-section of pile, and position of any change in

    .
    cross-section

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    .l.
    10. shoe or base details

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    11. head details
    12. length in ground
    13. tip Elevation
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    qa
    14. dimensions of any permanent casing
    15. concrete piles
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    concrete mix/grade

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    aggregate type and source


    cement type and cement replacement and type where used
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    admixtures
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    slump
    cube test results for pile and cap
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    date of casting of precast pile


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    et

    reinforcement

    16. steel piles


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    steel quality
    coating
    filling or core materials type and quality, if applicable

    (iii) Installation details.


    1. all piles
    dates and times of boring, driving and concreting of test pile
    difficulties and delays encountered
    date and time of casting concrete pile cap

    2. bored piles
    type of equipment used and method of boring
    temporary casing - diameter, type and length
    QCS 2014 Section 04: Foundations and Retaining Structures Page 47
    Part 04: Deep Foundations

    full log of pile borehole


    method of placing concrete
    Volume of concrete placed
    driven preformed and driven cast-in-place piles
    Method of support of hammer and pile driven length of pile or
    temporary casing at final set
    Hammer type, and size or weight
    Dolly and packing, type and condition
    Driving log (depth, hammer drop, blows per 250 mm,
    interruptions or breaks in driving)
    Final set in number of blows to produce penetration of 25 mm

    .
    Redrive check, time interval and set in number of blows to

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    .l.
    produce penetration of 25 mm or other agreed amount at final
    set and at redrive set, for a drop hammer or for a single acting

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    hammer the length of the drop or stroke, for a diesel hammer
    the length of the stroke and the blows per minute, for a double
    acting hammer the operating pressure and the number of blows
    per minute
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    qa
    condition of pile head or temporary casing after driving
    use of a follower
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    use of preboring
    use of jetting
    se

    lengthening
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    method of placing concrete


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    (iv) Test procedure.


    1. mass of kentledge
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    2. tension pile, ground anchorage or compression pile details


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    3. plan of test arrangement showing position and distances of kentledge


    et

    supports, rafts, tension or compression piles or ground anchorages, and


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    supports to pile movement reference system


    4. jack capacity
    5. method of load measurement
    6. method(s) of penetration or uplift measurement
    (v) Test results.
    1. in tabular form
    2. in graphical form: load plotted against pile head movement
    3. ambient temperature records during test.

    4.9.3 Low strain Integrity test

    1 This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in
    Section 2
    QCS 2014 Section 04: Foundations and Retaining Structures Page 48
    Part 04: Deep Foundations

    4.9.4 Grosshole Sonic Logging Test

    1 This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as
    mentioned in Section 2

    4.9.5 Calliper Logging Test

    1 This test shall be carried out in accordance with ASTM D6167 in a frequency as mentioned in
    Section 2

    4.9.6 Axial Tensile Load Test

    1 This test shall be carried out in accordance with ASTM D3689 in a frequency as mentioned in
    Section 2

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    4.9.7 Lateral Load Test

    .l.
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    1 This test shall be carried out in accordance with ASTM D3966 in a frequency as mentioned in
    Section 2

    4.9.8 Alternative Methods for Testing Piles


    ta
    qa
    1 Scope

    (a) This Part outlines the alternative methods for testing piles. A significant advance in
    as

    identifying the existence of defects in construction of piles has been the development
    and adoption of modern integrity testing systems which may be employed to check the
    se

    quality of construction when required by the Engineer.


    er

    (b) Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance
    distribution, and immediate settlement characteristics, hammer transfer energy
    ov

    (efficiency), and pile stresses during driving. The results obtained relate directly to
    dynamic loading conditions.
    o

    (c) Related Sections and Parts are as follows:


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    This Section
    et
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    Section 2

    2 Quality Assurance

    (a) The testing shall be carried out by an approved firm.


    (b) The interpretation of tests shall be carried out by persons competent in the test
    procedure, and the full test results and findings shall normally be given to the Engineer
    within 10 d of the completion of each phase of testing. Full details of the ground
    conditions, pile dimensions and construction method shall be made available to the
    specialist firm when required in order to facilitate interpretation of the tests.

    3 Integrity-testing of piles

    (a) General
    QCS 2014 Section 04: Foundations and Retaining Structures Page 49
    Part 04: Deep Foundations

    (i) Integrity-testing of piles is designed to give information about the physical


    dimensions, continuity and consistency of materials used in piles, and not to
    give direct information about the performance of piles under the conditions of
    loading. The methods available are normally applied to preformed concrete piles
    made in a single length, to steel piles and to cast-in-place concrete piles.
    (ii) This type of testing will not be regarded as a replacement for static load testing,
    but as a source of supplementary information.
    (iii) There is normally a limit to the length: diameter ratio of pile which can be
    successfully and fully investigated in this way, depending on the ground
    conditions.
    (iv) In the event that any anomaly is found in the results of such testing, the
    Engineer may call for further testing to be carried out in order to investigate the
    cause, nature and extent of the anomaly and whether the pile is satisfactory for

    .
    its intended use.

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    .l.
    (b) Method of Testing

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    (i) Where integrity-testing is called for but the method is not specified, the method
    to be adopted shall be approved by the Engineer and shall be one of the
    following
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    qa
    1. The sonic method.
    2. The vibration method.
    as

    3. The sonic logging method.


    (ii) Other methods may be adopted subject to the approval of the Engineer and
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    subject to satisfactory evidence of performance.


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    (c) Age of Piles at Time of Testing


    (i) In the case of cast-in-place concrete piles, integrity tests shall not be carried out
    ov

    until 7 d or more have elapsed after pile-casting, unless otherwise approved by


    the Engineer.
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    (d) Preparation of Pile Heads


    it
    et

    (i) Where the method of testing requires the positioning of sensing equipment on
    the pile head, the head shall be clean, free from water, laitance and loose
    m

    concrete and readily accessible for the purpose of testing.

    4 Dynamic pile-testing

    (a) General
    (i) Dynamic pile-testing involves monitoring the response of a pile to a heavy
    impact applied at the pile head. The impact is often provided by the pile-driving
    hammer and response is normally measured in terms of force and acceleration
    or displacement close to the pile head.
    (ii) The results directly obtained refer to dynamic loading conditions. Interpretation
    in terms of static loading requires soil- and pile-dependent adjustments, and
    corroboration from experience may be required to correlate dynamic testing with
    normal static load tests as specified in clause 4.9.1 of this Section.
    (iii) Details of the equipment to be used and of the method of analysis of test results
    shall be provided to the Engineer before the commencement of testing.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 50
    Part 04: Deep Foundations

    (b) Measuring Instruments


    (i) All instruments affixed to the pile for the purpose of measuring stress and
    movement, and all equipment for receiving and processing data shall be suitable
    for the purpose. The equipment required to be attached to the pile shall be
    appropriately positioned and fixed to the approval of the Engineer.
    (c) Hammer
    (i) The hammer and all other equipment used shall be capable of delivering an
    impact force sufficient to mobilise the equivalent specified test load without
    damaging the pile.
    (d) Preparation of the Pile Head
    (i) The preparation of the pile head for the application of the dynamic test load shall
    involve, where appropriate, trimming the head, cleaning and building up the pile

    .
    using materials which will at the time of testing safely withstand the impact

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    .l.
    stresses. The impact surface shall be flat and normal to the axis of the pile.

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    (e) Time of Testing
    (i) Dynamic load tests shall be carried out at appropriate and approved times after

    ta
    pile installation. The time between the completion of installation and testing for
    a preformed pile shall normally be more than 12 h, and in the case of a cast-in-
    qa
    place concrete piles shall be after the concrete has reached 75 % of its specified
    28 day strength so that the pile is not damaged under the impact stresses.
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    (f) Set Measurements


    (i) Where required and appropriate, the permanent penetration per blow and
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    temporary compression of the pile and soil system shall be measured


    independently of the instruments being used to record the dynamic test data.
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    (g) Results
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    (i) Initial the results shall be provided to the Engineer within 24 hours of the
    completion of a test. These shall include
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    1. The maximum force applied to the pile head.


    it
    et

    2. The maximum pile head velocity.


    3. The maximum energy imparted to the pile.
    m

    (ii) Normally within 10 d of the completion of testing final report shall be given to the
    Engineer which includes:
    1. Date of pile installation.
    2. Date of test.
    3. Pile identification number and location.
    4. Length of pile below ground surface.
    5. Total pile length, including projection above commencing surface at time
    of test.
    6. Length of pile from instrumentation position to tip.
    7. Hammer type, drop and other relevant details.
    8. Blow selected for analysis.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 51
    Part 04: Deep Foundations

    9. Test load achieved (i.e. total mobilised deduced static load).


    10. Pile head movement at equivalent design verification load.
    11. Pile head movement at equivalent design verification load plus 50 % of
    specified working load.
    12. Pile head movement at maximum applied test load.
    13. Permanent residual movement of pile head after each blow.
    14. Temporary compression.

    4.10 DESIGN METHODS AND DESIGN CONSIDERATIONS

    4.10.1 Design method

    .
    1 The design shall be based on one of the following approaches:

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    .l.
    (a) The results of static load tests, which have been demonstrated, by means of

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    calculations or otherwise, to be consistent with other relevant experience;
    (b) Empirical or analytical calculation methods whose validity has been demonstrated by
    static load tests in comparable situations;
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    qa
    (c) The results of dynamic load tests whose validity has been demonstrated by static load
    tests in comparable situations;
    (d) The observed performance of a comparable piles foundation, provided that this
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    approach is supported by the results of site investigation and ground testing.


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    2 Design values for parameters used in the calculations should be in general accordance with
    design parameters from geotechnical investigations report, but the results of load tests may
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    also be taken into account in selecting parameter values.


    ov

    3 Static load tests may be carried out on trial piles, installed for test purposes only, before the
    design is finalized, or on working piles, which form part of the foundation.
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    4.10.2 Verification of Resistance for Structural and Ground Limit States in Persistent and
    it

    Transient Situations
    et
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    1 When considering a limit state of rupture or excessive deformation of a structural element or


    section of the ground (Structural and Geotechnical), it shall be verified in accordance with
    (Eurocode1997-1) or equivalent.

    4.10.3 Design Considerations

    1 The behavior of individual piles and pile groups and the stiffness and strength of the structure
    connecting the piles shall be considered.

    2 In selecting calculation methods and parameter values and in using load test results, the
    duration and variation in time of the loading shall be considered.

    3 Planned future placement or removal of overburden or potential changes in the ground-water


    regime shall be considered, both in calculations and in the interpretation of load test results.

    4 The choice of type of pile, including the quality of the pile material and the method of
    installation, shall take into account:
    QCS 2014 Section 04: Foundations and Retaining Structures Page 52
    Part 04: Deep Foundations

    (a) the ground and ground-water conditions on the site, including the presence or
    possibility of obstructions in the ground;
    (b) the stresses generated in the pile during installation;
    (c) the possibility of preserving and checking the integrity of the pile being installed;
    (d) the effect of the method and sequence of pile installation on piles, which have already
    been installed and on adjacent structures or services;
    (e) the tolerances within, which the pile can be installed reliably;
    (f) the deleterious effects of chemicals in the ground;
    (g) the possibility of connecting different ground-water regimes;
    (h) the handling and transportation of piles;
    (i) the effects of pile construction on neighboring buildings.

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    5 In considering the aspects listed above, the following items should receive attention:

    rw
    (a) the spacing of the piles in pile groups;
    (b) displacement or vibration of adjacent structures due to pile installation;
    (c) the type of hammer or vibrator used;
    ta
    qa
    (d) the dynamic stresses in the pile during driving;
    (e) for those types of bored pile where a fluid is used inside the borehole, the need to
    as

    keep the pressure of the fluid at a level to ensure that the borehole will not collapse
    and that hydraulic failure of the base will not occur;
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    (f) cleaning of the base and sometimes the shaft of the borehole, especially under
    bentonite, to remove remolded materials;
    er

    (g) local instability of a shaft during concreting, which may cause a soil inclusion within
    ov

    the pile;
    (h) ingress of soil or water into the section of a cast-in-situ pile and possible disturbance
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    of wet concrete by the flow of water through it;


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    (i) the effect of unsaturated sand layers around a pile extracting water from the
    et

    concrete;
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    (j) the retarding influence of chemicals in the soil;


    (k) soil compaction due to the driving of displacement piles;
    (l) soil disturbance due to the boring of a pile shaft.

    4.11 AXIALLY LOADED PILES

    4.11.1 Limit state design

    1 The design shall demonstrate that exceeding the following limit states is sufficiently
    improbable:

    (a) ultimate limit states of compressive or tensile resistance failure of a single pile;
    (b) ultimate limit states of compressive or tensile resistance failure of the pile foundation
    as a whole;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 53
    Part 04: Deep Foundations

    (c) ultimate limit states of collapse or severe damage to a supported structure caused by
    excessive displacement or differential displacements of the pile foundation;
    (d) serviceability limit states in the supported structure caused by displacement of the piles.

    2 Normally the design should consider the margin of safety with respect to compressive or
    tensile resistance failure, which is the state in which the pile foundation displaces significantly
    downwards or upwards with negligible increase or decrease of resistance.

    3 For piles in compression it is often difficult to define an ultimate limit state from a load
    settlement plot showing a continuous curvature. In these cases, settlement of the pile top
    equal to 10% of the pile base diameter should be adopted as the "failure" criterion.

    4 For piles that undergo significant settlements, ultimate limit states may occur in supported
    structures before the resistance of the piles is fully mobilized. In these cases a cautious

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    estimate of the possible range of the settlements shall be adopted in design.

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    4.11.2 Compressive Ground Resistance

    1 To demonstrate that the pile foundation will support the design load with adequate safety

    ta
    against compressive failure, the following inequality shall be satisfied for all ultimate limit
    qa
    state load cases and load combinations:
    Fc Rc
    as

    Where
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    Fc: design axial compression load on a pile or a group of piles


    er

    Rc: design value


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    2 In principle Fc should include the weight of the pile itself and Rc should include the
    overburden pressure of the soil at the foundation base. However these two items may be
    o

    disregarded if they cancel approximately. They need not cancel if:


    it

    (a) downdrag is significant;


    et

    (b) the soil is very light,


    m

    (c) the pile extends above the surface of the ground.

    3 For piles in groups, two failure mechanisms shall be taken into account:

    (a) compressive resistance failure of the piles individually;


    (b) compressive resistance failure of the piles and the soil contained between them acting
    as a block.
    NOTE: The design resistance shall be taken as the lower value caused by these two
    mechanisms.

    4 The compressive resistance of the pile group acting as a block may be calculated by
    treating the block as a single pile of large diameter.

    5 The stiffness and strength of the structure connecting the piles in the group shall be
    considered when deriving the design resistance of the foundation.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 54
    Part 04: Deep Foundations

    6 If the piles support a stiff structure, advantage may be taken of the ability of the structure
    to redistribute load between the piles. A limit state will occur only if a significant numbe r of
    piles fail together; therefore a failure mode involving only one pile need not be considered.

    7 If the piles support a flexible structure, it should be assumed that the compressive
    resistance of the weakest pile governs the occurrence of a limit state.

    8 Special attention should be given to possible failure of edge piles caused by inclined or
    eccentric loads from the supported structure.

    9 If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer
    on the compressive resistance of the foundation shall be considered.

    10 The strength of a zone of ground above and below the pile base shall be taken into
    account when calculating the pile base resistance.

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    rw
    NOTE: This zone may extend several diameters above and below the pile base. Any weak
    ground in this zone has a relatively large influence on the base resistance.

    11 ta
    Punching failure should be considered if weak ground is present at a depth of less than 4
    qa
    times the base diameter below the base of the pile.

    12 Where the pile base diameter exceeds the shaft diameter, the possible adverse effect
    as

    shall be considered.
    se

    13 For open-ended driven tube or box-section piles with openings of more than 500 mm in
    any direction, and without special devices inside the pile to induce plugging, the base
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    resistance should be limited to the smaller of:


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    (a) the shearing resistance between the soil plug and the inside face of the pile;
    (b) the base resistance derived using the cross-sectional area of the base.
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    4.11.3 Ultimate compressive resistance from static load tests


    et

    1 The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be
    m

    specified in the Geotechnical Design Report.

    2 Trial piles to be tested in advance shall be installed in the same manner as the piles that will
    form the foundation and shall be founded in the same stratum.

    3 If the diameter of the trial pile differs from that of the working piles, the possible difference in
    performance of piles of different diameters should be considered in assessing the
    compressive resistance to be adopted.

    4 In the case of a very large diameter pile, it is often impractical to carry out a load test on a full
    size trial pile. Load tests on smaller diameter trial piles may be considered provided that:

    (a) the ratio of the trial pile diameter/working pile diameter is not less than 0,5;
    (b) the smaller diameter trial pile is fabricated and installed in the same way as the piles
    used for the foundation;
    QCS 2014 Section 04: Foundations and Retaining Structures Page 55
    Part 04: Deep Foundations

    (c) the trial pile is instrumented in such a manner that the base and shaft resistance can be
    derived separately from the measurements.
    NOTE: This approach should be used with caution for open-ended driven piles because of
    the influence of the diameter on the mobilisation of the compressive resistance of a soil plug
    in the pile.

    5 In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a
    displacement that equals the criterion for the verification of the ultimate limit state determined
    from the load test results, shall be corrected. The correction shall be achieved by subtracting
    the measured, or the most unfavorable, positive shaft resistance in the compressible stratum
    and in the strata above, where negative skin friction develops, from the loads measured at
    the pile head.

    6 During the load test of a pile subject to downdrag, positive shaft friction will develop along the

    .
    total length of the pile. The maximum test load applied to the working pile should be in excess

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    .l.
    of the sum of the design external load plus twice the downdrag force.

    rw
    7 When deriving the ultimate characteristic compressive resistance from values measured in
    one or several pile load tests, an allowance shall be made for the variability of the ground and
    the variability of the effect of pile installation.
    ta
    qa
    8 The systematic and random components of the variations in the ground shall be recognized
    in the interpretation of pile load tests.
    as

    9 The records of the installation of the test pile(s) shall be checked and any deviation from the
    normal execution conditions shall be accounted for.
    se

    10 The characteristic compressive resistance of the ground may be derived from the
    er

    characteristic values of the base resistance and of the shaft resistance in accordance with
    Eurocode1997-1.
    ov

    4.11.4 Ultimate compressive resistance from ground test results


    o

    1 Methods for assessing the compressive resistance of a pile foundation from ground test
    it

    results shall have been established from pile load tests and from comparable experience.
    et
    m

    2 A model factor may be introduced as described as following to ensure that the predicted
    compressive resistance is sufficiently safe :

    (a) the range of uncertainty in the results of the method of analysis;


    (b) any systematic errors known to be associated with the method of analysis

    3 In assessing the validity of a model based on ground test results, the following items should
    be considered:

    (a) soil type, including grading, mineralogy, angularity, density, pre-consolidation,


    compressibility and permeability;
    (b) method of installation of the pile, including method of boring or driving;
    (c) length, diameter, material and shape of the shaft and of the base of the pile (e.g.
    enlarged base);
    (d) method of ground testing.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 56
    Part 04: Deep Foundations

    4.11.5 Ultimate compressive resistance from dynamic impact tests

    1 Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration
    versus time during the impact event is used to assess the resistance of individual
    compression piles, the validity of the result shall have been demonstrated by previous
    evidence of acceptable performance in static load tests on the same pile type of similar
    length and cross-section and in similar ground conditions.

    2 When using a dynamic impact load test, the driving resistance of the pile should be
    measured directly on the site in question.

    NOTE A load test of this type can also include a process of signal matching to
    measured stress wave figures. Signal matching enables an approximate evaluation of shaft
    and base resistance of the pile as well as a simulation of its load-settlement behaviour.

    .
    3 The impact energy shall be high enough to allow for an appropriate interpretation of

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    .l.
    the pile capacity at a correspondingly high enough strain level.

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    4 The design value of the compressive resistance of the pile could be calculated and
    verified according to Eurocode1997-1.

    4.11.6 ta
    Ultimate compressive resistance by applying pile driving formulae
    qa
    1 Pile driving formulae shall only be used if the stratification of the ground has been
    determined.
    as

    2 If pile driving formulae are used to assess the ultimate compressive resistance of individual
    se

    piles in a foundation, the validity of the formulae shall have been demonstrated by previous
    experimental evidence of acceptable performance in static load tests on the same type of
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    pile, of similar length and cross-section, and in similar ground conditions.


    ov

    3 For end-bearing piles driven into non-cohesive soil, the design value of the compressive
    resistance shall be assessed by the same procedure as in 4.11.5.
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    4 When a pile driving formula is applied to verify the compression resistance of a pile, the pile
    it

    driving test should have been carried out on at least 5 piles distributed at sufficient spacing in
    et

    the piling area in order to check a suitable blow count for the final series of blows.
    m

    5 The penetration of the pile point for the final series of blows should be recorded for each pile.

    4.11.7 Ultimate compressive resistance from wave equation analysis

    1 Wave equation analysis shall only be used where stratification of the ground has been determined
    by borings and field tests.

    2 Where wave equation analysis is used to assess the resistance of individual compression piles,
    the validity of the analysis shall have been demonstrated by previous evidence of acceptable
    performance in static load tests on the same pile type, of similar length and cross- section, and in
    similar ground conditions.

    3 The design value of the compressive resistance derived from the results of wave equation analysis
    of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 57
    Part 04: Deep Foundations

    NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving
    equipment without stress wave measurements on site. The method is usually applied to
    study hammer performance, dynamic soil parameters and stresses in the pile during driving.
    It is also, on the basis of the models, possible to determine the required driving resistance
    (blow count) that is usually related to the expected compressive resistance of the pile.

    4.11.8 Ground tensile resistance

    1 The design of piles in tension shall be consistent with the design rules given in 4.11.2, where
    applicable. Design rules that are specific for foundations involving piles in tension are presented
    below.

    2 To verify that the foundation will support the design load with adequate safety against a failure in
    tension, the following inequality shall be satisfied for all ultimate limit state load cases and load
    combinations in accordance with Eurocode1997-1.

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    3 For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the

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    pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.

    4 When considering the uplift of the block of ground containing the piles the shear resistance along

    ta
    the sides of the block may be added to the resisting forces.
    qa
    5 Normally the block effect will govern the design tensile resistance if the distance between the piles
    is equal to or less than the square root of the product of the pile diameter and the pile penetration
    into the main resisting stratum.
    as

    6 The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft
    se

    resistances of individual piles in the group, shall be considered when assessing the tensile
    resistance of a group of piles.
    er

    7 The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be
    ov

    considered.
    o

    8 Comparable experience based on pile load tests should be applied to appraise this effect.
    it
    et

    4.11.9 Ultimate tensile resistance from pile load tests


    m

    1 Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in
    accordance with 4.9.1 and with regard to 4.11.3.

    2 The design tensile resistance could be calculated and verified according to Eurocode1997-1.

    4.11.10 Ultimate tensile resistance from ground test results

    1 Methods for assessing the tensile resistance of a pile foundation from ground test results shall
    have been established from pile load tests and from comparable experience.

    2 A model factor may be introduced as following to ensure that the predicted tensile resistance is
    sufficiently safe.

    (a) the range of uncertainty in the results of the method of analysis;


    (b) any systematic errors known to be associated with the method of analys is
    QCS 2014 Section 04: Foundations and Retaining Structures Page 58
    Part 04: Deep Foundations

    3 The design value of tensile resistance of a pile could be calculated and verified according to
    Eurocode1997-1.

    4.11.11 Vertical displacements of pile foundations

    1 Vertical displacements under serviceability limit state conditions shall be assessed and checked.

    2 When calculating the vertical displacements of a pile foundation, the uncertainties involved in the
    calculation model and in determining the relevant ground properties should be taken into account.
    Hence it should not be overlooked that in most cases calculations will provide only an approximate
    estimate of the displacements of the pile foundation.

    NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety
    requirements for the ultimate limit state design are normally sufficient to prevent a
    serviceability limit state in the supported structure.

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    4.11.12 Pile foundations in compression

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    1 The occurrence of a serviceability limit state in the supported structure due to pile settlements shall
    be checked, taking into account downdrag, where probable.

    ta
    NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very
    qa
    hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to
    satisfy serviceability limit state conditions.
    as

    2 Assessment of settlements shall include both the settlement of individual piles and the settlement
    due to group action.
    se

    3 The settlement analysis should include an estimate of the differential settlements that may occur.
    er

    4 When no load test results are available for an analysis of the interaction of the piled foundation with
    ov

    the superstructure, the load-settlement performance of individual piles should be assessed on


    empirically established safe assumptions.
    o

    4.11.13 Pile foundations in tension


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    et

    1 The assessment of upward displacements shall be done and Particular attention should be paid to
    the elongation of the pile material.
    m

    2 When very severe criteria are set for the serviceability limit state, a separate check of the upward
    displacements shall be carried out.

    4.12 TRANSVERSELY LOADED PILES

    4.12.1 Design method

    1 The design of piles subjected to transverse loading shall be consistent with the design rules given
    in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to
    transverse loading are presented below.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 59
    Part 04: Deep Foundations

    2 To demonstrate that a pile will support the design transverse load with adequate safety against
    failure, the following inequality shall be satisfied for all ultimate limit state load cases and load
    combinations:

    Ftr Rtr

    Where;
    Ftr: design value of the transverse load on a pile or a pile foundation
    Rtr : design resistance of transversally loaded pile

    3 One of the following failure mechanisms should be considered:

    (a) for short piles, rotation or translation as a rigid body;

    .
    (b) for long slender piles, bending failure of the pile, accompanied by local yielding and

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    .l.
    displacement of the soil near the top of the pile.

    rw
    4 The group effect shall be considered when assessing the resistance of transversely loaded piles.

    5 It should be considered that a transverse load applied to a group of piles may result in a

    ta
    combination of compression, tension and transverse forces in the individual piles.
    qa
    4.12.2 Transverse load resistance from pile load tests
    as

    1 Transverse pile load tests shall be carried out in accordance with 4.9.6.
    se

    2 Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not
    normally be continued to a state of failure. The magnitude and line of action of the test load should
    simulate the design loading of the pile.
    er
    ov

    3 An allowance shall be made for the variability of the ground, particularly over the top few meters of
    the pile, when choosing the number of piles for testing and when deriving the design transverse
    resistance from load test results.
    it o

    4 Records of the installation of the test pile(s) should be checked, and any deviation from the normal
    et

    construction conditions should be accounted for in the interpretation of the pile load test results.
    For pile groups, the effects of interaction and head fixity should be accounted for when deriving the
    m

    transverse resistance from the results of load tests on individual test piles.

    4.12.3 Transverse load resistance from ground test results and pile strength parameters

    1 The transverse resistance of a pile or pile group shall be calculated using a compatible set of
    structural effects of actions, ground reactions and displacements.

    2 The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile
    in the ground.

    3 The calculation of the transverse resistance of a long slender pile may be carried out using the
    theory of a beam loaded at the top and supported by a deformable medium characterized by a
    horizontal modulus of subgrade reaction.

    4 The degree of freedom of rotation of the piles at the connection with the structure shall be taken
    into account when assessing the foundations transverse resistance.
    QCS 2014 Section 04: Foundations and Retaining Structures Page 60
    Part 04: Deep Foundations

    4.12.4 Transverse displacement

    1 The assessment of the transverse displacement of a pile foundation shall take into account:

    (a) the stiffness of the ground and its variation with strain level;
    (b) the flexural stiffness of the individual piles;
    (c) the moment fixity of the piles at the connection with the structure;
    (d) the group effect;
    (e) the effect of load reversals or of cyclic loading

    2 A general analysis of the displacement of a pile foundation should be based on expected degrees
    of kinematic freedom of movement.

    l .
    END OF PART

    .l.
    rw
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    QCS 2014 Section 04: Foundations & Retaining Structures Page 2
    Part 05: Retaining Structures

    5 RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2

    5.1 GENERAL---------------------------------------------------------------------------------------------------------- 2

    5.2 LIMIT STATES ---------------------------------------------------------------------------------------------------- 2


    5.2.2 Ultimate Limit State ---------------------------------------------------------------------------------------------- 2
    5.2.3 Serviceability Limit State ---------------------------------------------------------------------------------------- 3
    5.3 ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3
    5.3.1 Actions -------------------------------------------------------------------------------------------------------------- 3
    5.3.2 Geometrical data ------------------------------------------------------------------------------------------------- 4
    5.3.3 Design Situations ------------------------------------------------------------------------------------------------- 4
    5.4 DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5

    5.5 DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6

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    5.5.1 General ------------------------------------------------------------------------------------------------------------- 6
    5.5.2 At rest values of earth pressure------------------------------------------------------------------------------- 7

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    5.5.3 Limiting values of earth pressure ----------------------------------------------------------------------------- 7
    5.5.4 Intermediate values of earth pressure ----------------------------------------------------------------------- 7
    5.5.5
    5.6 ta
    Compaction effects ---------------------------------------------------------------------------------------------- 7
    WATER PRESSURES ------------------------------------------------------------------------------------------ 8
    qa
    5.7 ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8
    as

    5.7.1 General ------------------------------------------------------------------------------------------------------------- 8


    5.7.2 Overall stability ---------------------------------------------------------------------------------------------------- 8
    se

    5.7.3 Foundation failure of gravity walls ---------------------------------------------------------------------------- 8


    5.7.4 Rotational failure of embedded walls ------------------------------------------------------------------------ 8
    er

    5.7.5 Vertical failure of embedded walls --------------------------------------------------------------------------- 9


    5.7.6 Structural design of retaining structures -------------------------------------------------------------------- 9
    ov

    5.7.7 Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9


    5.8 SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9
    o

    5.8.1 General ------------------------------------------------------------------------------------------------------------- 9


    it

    5.8.2 Displacements ---------------------------------------------------------------------------------------------------- 9


    et
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    QCS 2014 Section 04: Foundations & Retaining Structures Page 2
    Part 05: Retaining Structures

    5 RETAINING STRUCTURES

    5.1 GENERAL

    1 The provisions of this Part 5 apply to retaining structures in general. These are structures
    used to retain ground comprising soil, rock or backfill and water and this at an angle steeper
    than the angle they would normally adopt without the presence of those structures. Common
    retaining structures used within the state of Qatar taking into account the prevailing geologic
    conditions are:

    (a) Sheet Piles


    (b) Bored and Cast in Place Concrete Piles

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    (i) Contiguous Piles

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    (ii) Secant Piles

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    (c) Diaphragm Walls
    (d) Composite Shoring Systems
    (e) Concrete Retaining Walls ta
    qa
    (i) Cantilever Retaining Wall
    (ii) Counter Fort Retaining Wall
    as

    (iii) Gravity Retaining Wall


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    (iv) Buttressed Retaining Wall


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    (f) Reinforced Soil Retaining Structures


    (i) Geogrid and Geotextile Reinforced Earth Systems
    ov

    (ii) Galvanized Strips Reinforced Earth System


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    (g) Soil and Rock Nailing Systems


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    2 This revision of Section 4 Part 5 is considered preliminary and shall be reviewed and
    et

    amended as needed in the next revision to elaborate on various subjects not covered herein.
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    3 This revision of Section 4 Part 5 is based generally on EN1997-1:2004+A1:2013


    Eurocode 7.

    4 Section 4 Part 5 will cover at this stage the general design aspects knowing that the
    construction procedures shall be added in future revisions of this Section. Hence, at this
    stage, the construction related subjects of the retaining structures will follow relevant Parts of
    the QCS.

    5.2 LIMIT STATES

    1 During the design of retaining structures the following typical limit states should be
    considered:

    5.2.2 Ultimate Limit State

    1 Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 3
    Part 05: Retaining Structures

    2 Foundation failure of retaining structures with footings: it should be demonstrated that the
    foundation pressures (lateral and vertical) do not exceed neither the ground allowable
    bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to
    water seepage should also be included in the analysis.

    3 Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a
    rigid body.

    4 Failure of embedded walls by rotation or horizontal translation or by lack of vertical


    equilibrium.

    5 Failure of a structural element such as a wall, anchorage, wale or strut, including failure of
    the connection between those elements.

    6 Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable

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    leakage of water, or transport of soil particles through or under the wall caused by excessive

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    hydraulic gradients.

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    5.2.3 Serviceability Limit State

    1
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    Unacceptable movement of the retaining structure, which may affect the appearance or
    functionality of the structure itself, or other neighbouring structures or utilities influenced by
    qa
    the movement.
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    2 Unacceptable change in the groundwater regime.


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    5.3 ACTIONS AND GEOMETRICAL DATA


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    5.3.1 Actions
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    1 Generally, the forces exerted on retaining structure with values assumed known at the
    beginning of the calculation are considered as 'actions', while forces with initially unknown
    values, to be determined by the interaction of the retaining structure with support elements
    o

    (ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following
    it

    actions are to be taken into account:


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    (a) Weight of backfill material


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    (b) Surcharges
    (c) Weight of water
    (d) Wave forces for marine projects
    (e) Seepage forces
    (f) Collision forces
    (g) Temperature effects
    (h) Forces from propping elements (i.e. post-tensioned anchors)
    (i) Siesmic related effects

    2 The above actions should result in the determination of various earth pressures acting on the
    retaining structure.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 4
    Part 05: Retaining Structures

    5.3.2 Geometrical data

    1 This paragraph covers the uncertainties in the geometrical data namely excavation and water
    levels. In general, small variations in geometrical data are considered to be covered by the
    safety factors included in the calculations. However, since the design of retaining structures
    is sensitive to ground and water levels, special requirements are included in this paragraph,
    mainly for unforeseen over-dig in front of the wall and groundwater levels change on both
    sides of the wall.

    2 Unforeseen over-dig in front of the wall

    In Ultimate Limit State design calculations, where the wall stability depends on the earth
    resistance in front of the wall, the level of the resisting soil should be lowered below the
    nominally expected level by an amount which depends on the degree of control on the
    excavation level. With a normal degree of control the expected difference in resisting soil

    .
    level should be:

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    (a) Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for
    cantilever walls;

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    (b) Equal to 10% of the distance between the lowest support and the excavation level (up
    to a maximum of 0.5 m), for supported walls.

    3 Groundwater levels in front of and behind the wall ta


    qa
    The selection of the levels of the phreatic surfaces in front of and behind the wall must
    consider long-term variations of the groundwater regime and/or the ground permeability, the
    as

    presence of perched or artesian aquifers and the possibility that drainage behind the wall
    may cease to function with time.
    se

    5.3.3 Design Situations


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    1 The following conditions shall be considered during the design of retaining structures:
    ov

    (a) Anticipated variations in soil properties


    (b) Variations in actions and the ways they are combined
    it o

    (c) Excavation, scour or erosion in front of the retaining structure


    et

    (d) The effect of compaction of the backfill behind the retaining structure
    m

    (e) The effect of anticipated future structures and surcharge loads/unloads


    (f) Anticipated ground movements
    (g) Inclination of the wall to the vertical
    (h) Variations in groundwater table and the seepage forces in the ground
    (i) Horizontal as well as vertical equilibrium for the entire retaining structure
    (j) The shear strength and weight density of the ground
    (k) The rigidity of the wall and the supporting system
    (l) The wall roughness
    (m) Seismic effect on the various forces
    QCS 2014 Section 04: Foundations & Retaining Structures Page 5
    Part 05: Retaining Structures

    5.4 DESIGN AND CONSTRUCTION CONSIDERATIONS

    1 The design of retaining structures requires consideration of all relevant Ultimate Service
    States and Service Limit States.

    2 For retaining structures without strict serviceability requirements, the geometry is usually
    determined by Ultimate Limit State design calculations and checked by Service Limit State
    calculations (if relevant). For the retaining structures with strict serviceability requirements,
    the Service Limit State requirements often govern the design.

    3 The design and construction considerations should cover the following:

    (a) Demonstrate that vertical equilibrium can be achieved for the assumed pressure
    distributions and actions on the wall.

    .
    (b) Verification of vertical equilibrium may be achieved by reducing the wall friction

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    parameters.

    rw
    (c) Retaining walls should be designed in such a way that there are visible signs of the
    approach of an ultimate limit state. The design should prevent brittle failure of the
    structure, e.g. sudden collapse without conspicuous preliminary deformations.
    (d) ta
    A critical limit state should be considered to occur if the wall has displaced enough to
    qa
    cause damage to nearby structures or services. Although collapse of the wall may not
    be imminent, the degree of damage may considerably exceed a serviceability limit
    state in the supported structure.
    as

    (e) The design methods and partial factor values recommended by EN1997-
    1:2004+A1:2013 are usually sufficient to prevent the occurrence of ultimate limit
    se

    states in nearby structures, provided that the soils involved are of at least medium
    er

    density or firm consistency and adequate construction methods and sequences are
    adopted. Special care should be taken, however, with some highly over-consolidated
    ov

    clay deposits in which large at rest horizontal stresses may induce substantial
    movements in a wide area around excavations.
    o

    (f) The complexity of the interaction between the ground and the retaining structure
    it

    sometimes makes it difficult to design a retaining structure in detail before the actual
    et

    execution starts. In this case, use of the observational method for the design should be
    considered. The observational method consists of setting criteria enabling monitoring
    m

    during construction, allowing necessary corrective actions to be taken to rectify the


    design. Hence, the following requirements shall be set before construction:
    (i) Acceptable limits of behaviour
    (ii) The range of potential behaviour shall be analysed showing acceptable
    probability that the actual behaviour will be within the acceptable limits
    (iii) A plan of monitoring shall be established (including necessary instruments and
    procedures) enabling the comparison of the actual behaviour to the acceptable
    limits. The monitoring shall allow early detection of nonconformities, allowing
    enough time for corrective actions to be taken successfully.
    (iv) A list of contingency actions shall be established which could be used if the
    actual observed behaviour is outside of the acceptable limits.
    (g) The effects of constructing the wall, including:
    (i) The provision of temporary support to the sides of excavations;
    QCS 2014 Section 04: Foundations & Retaining Structures Page 6
    Part 05: Retaining Structures

    (ii) The changes of in situ stresses and resulting ground movements caused both
    by the wall excavation and its construction;
    (iii) Disturbance of the ground due to driving or boring operations;
    (iv) Provision of access for construction;

    (h) The required degree of water tightness of the finished wall;


    (i) The practicability of constructing the wall to reach a stratum of low permeability, so
    forming a water cut-off. The resulting equilibrium ground-water flow problem shall be
    assessed;
    (j) The practicability of forming ground anchorages in adjacent ground;
    (k) The practicability of excavating between any propping of retaining walls;

    .
    (l) The ability of the wall to carry vertical load;

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    (m) The ductility of structural components;

    rw
    (n) Access for maintenance of the wall and any associated drainage measures;
    (o) The appearance and durability of the wall and any anchorages;
    (p)
    ta
    For sheet piling, the need for a section stiff enough to be driven to the design
    qa
    penetration without loss of interlock;
    (q) The stability of borings or slurry trench panels while they are open;
    as

    (r) For fill, the nature of materials available and the means used to compact them
    adjacent to the wall.
    se

    (s) Drainage systems


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    If the safety and serviceability of the designed structure depend on the successful
    performance of a drainage system, the consequences of its failure shall be
    ov

    considered, taking into account both safety and cost of repair. One of the following
    conditions (or a combination of them) shall apply:
    o

    (i) A maintenance program for the drainage system shall be specified and the
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    design shall allow access for this purpose;


    et

    (ii) It shall be demonstrated both by comparable experience and by assessment of


    m

    any water discharge that the drainage system will operate adequately without
    maintenance.

    The quantities, pressures and eventual chemical content of any water discharge
    should be taken into account.

    5.5 DETERMINATION OF EARTH PRESSURES

    5.5.1 General

    1 The Determination of the earth pressures shall take into account the acceptable mode and
    amount of any movement and strain, which may occur at the limit state under consideration.

    2 In the following context the words "earth pressure" should also be used for the total earth
    pressure from soft and weathered rocks and should include the pressure of ground-water.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 7
    Part 05: Retaining Structures

    3 Calculations of the magnitudes of earth pressures and directions of forces resulting from
    them shall take account of the issues highlighted under paragraph 5.3.3.

    4 The amount of mobilized wall friction and adhesion should be considered as a function of:

    (a) The strength parameters of the ground


    (b) The friction properties of the wall-ground interface
    (c) The direction and amount of movement of the wall relative to the ground
    (d) The ability of the wall to support any vertical forces resulting from wall friction and
    adhesion

    5 A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a
    design wall ground interface parameter d k. cv ;d . k should not exceed 2/3 for precast

    .
    concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be

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    assumed. For a steel sheet pile in clay under undrained conditions immediately after driving,
    no adhesive or frictional resistance should be assumed. Increases in these values may take

    rw
    place over a period of time.

    ta
    6 In the case of structures retaining rock masses, calculations of the ground pressures shall
    take into account the effects of discontinuities, with particular attention to their orientation,
    qa
    spacing, aperture, roughness and the mechanical characteristics of any joint filling material.

    7 Account shall be taken of any swelling potential of the ground when calculating the pressures
    as

    on the retaining structure.


    se

    5.5.2 At rest values of earth pressure


    er

    1 When no movement of the wall relative to the ground takes place, the earth pressure shall be
    calculated from the at rest state of stress. The determination of the at-rest state shall take
    ov

    into account the stress history of the ground.

    5.5.3 Limiting values of earth pressure


    it o

    1 Limiting values of earth pressures shall be determined taking into account the relative
    et

    movement of the soil and the wall at failure and the corresponding shape of the failure
    m

    surface.

    5.5.4 Intermediate values of earth pressure

    1 Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize
    the limiting values. The determination of the intermediate values of earth pressure shall take
    into account the amount of wall movement and its direction relative to the ground.

    2 The intermediate values of earth pressures may be calculated using, for example, various
    empirical rules, spring constant methods or finite element methods.

    5.5.5 Compaction effects

    1 The determination of earth pressures acting behind the wall shall take into account the
    additional pressures generated by any placing of backfill and the procedures adopted for its
    compaction.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 8
    Part 05: Retaining Structures

    5.6 WATER PRESSURES

    1 Determination of characteristic and design water pressures shall take account of water levels
    both above and in the ground.

    2 When checking the ultimate and serviceability limit water pressures shall be accounted for in
    the combinations of actions considering the possible risks of flooding or change in
    groundwater levels from either sides of the retaining structure.

    3 For structures retaining earth of medium or low permeability (silts and clays), water pressures
    should normally be assumed to act behind the wall. Unless a reliable drainage system is
    installed, or infiltration is prevented, the values of water pressures should normally
    correspond to a water table at the surface of the retained material.

    4 Where sudden changes in a free water level may occur, both the non-steady condition

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    occurring immediately after the change and the steady condition shall be examined.

    rw
    5 Where no special drainage or flow prevention measures are taken, the possible effects of
    water-filled tension or shrinkage cracks shall be considered.

    5.7 ULTIMATE LIMIT STATE DESIGN


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    5.7.1 General
    as

    1 The design of retaining structures shall be checked at the ultimate limit state for the design
    situations appropriate to that state, as specified in 5.3.3, using the design actions or action
    se

    effects and design resistances.


    er

    2 All relevant limit modes shall be considered. These will include, as a minimum, limit modes of
    the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.
    ov

    3 Calculations for ultimate limit states shall establish that equilibrium can be achieved using the
    design actions or effects of actions and the design strengths or resistances. Compatibility of
    o

    deformations shall be considered in assessing design strengths or resistances.


    it
    et

    5.7.2 Overall stability


    m

    1 Principles and calculations should be used as appropriate to demonstrate that an overall


    stability failure will not occur and that the corresponding deformations are sufficiently small
    taking into account progressive failure and liquefaction into account as relevant.

    5.7.3 Foundation failure of gravity walls

    1 The principles of foundation design shall be used as appropriate to demonstrate that a


    foundation failure is sufficiently remote and that deformations will be acceptable. Both
    bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should
    be verified as a minimum.

    5.7.4 Rotational failure of embedded walls

    1 It shall be demonstrated by equilibrium calculations that embedded walls have sufficient


    penetration into the ground to prevent rotational failure. As a minimum, limit modes of the
    types illustrated in Figure 5.3 should be considered.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 9
    Part 05: Retaining Structures

    2 The design magnitude and direction of shear stress between the soil and the wall shall be
    consistent with the relative vertical displacement, which would occur in the design situation.

    5.7.5 Vertical failure of embedded walls

    1 It shall be demonstrated that vertical equilibrium can be achieved using the design soil
    strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode
    of the type illustrated in Figure 5.4 should be considered.

    2 Where downward movement of the wall is considered, upper design values shall be used in
    the calculation of pre-stressing forces, such as those from ground anchorages, which have a
    vertical downward component. The design magnitude and direction of shear stress between
    the soil and the wall shall be consistent with the check for vertical and rotational equilibrium.
    If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using
    the principles of Pile Foundations Design.

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    5.7.6 Structural design of retaining structures

    rw
    1 Retaining structures, including their supporting structural elements such as anchorages and
    props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013

    ta
    2.4 Geotechnical Design by Calculation and EN1992, EN1993, EN1995 and EN1996. As a
    qa
    minimum, limit modes of the types illustrated in Figure 5.5 should be considered.

    5.7.7 Failure by pull-out of anchorages


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    1 It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground
    se

    anchorages. Anchors shall be designed in accordance with Anchorage Design procedures


    with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be
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    considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also
    be considered.
    ov

    5.8 SERVICEABILITY LIMIT STATE DESIGN


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    5.8.1 General
    it
    et

    1 The design of retaining structures shall be checked at the serviceability limit state using the
    m

    appropriate design situations as specified in 5.3.3. The assessment of design values of earth
    pressures should take account of the initial stress, stiffness and strength of the ground and
    the stiffness of the structural elements.

    2 The design values of earth pressures should be derived taking account of the allowable
    deformation of the structure at its serviceability limit state. These pressures need not
    necessarily be limiting values.

    5.8.2 Displacements

    1 Limiting values for the allowable displacements of walls and the ground adjacent to them
    shall be established for a particular deformation is the value at which a serviceability limit
    state, such as unacceptable cracking or displacement of adjacent structures or utilities, is
    deemed to occur. This limiting value shall be agreed during the design, taking into account
    the tolerance to displacements of supported structures and services.
    QCS 2014 Section 04: Foundations & Retaining Structures Page 10
    Part 05: Retaining Structures

    2 If the initial cautious estimate of displacement exceeds the limiting values, the design shall be
    justified by a more detailed investigation including displacement calculations.

    3 It shall be considered to what extent variable actions, such as vibrations caused by traffic
    loads behind the retaining wall, contribute to the wall displacement.

    4 Displacement calculations should also be considered in the following cases:

    (a) where the wall retains more than 6m of cohesive soil of low plasticity,
    (b) where the wall retains more than 3m of soils of high plasticity;
    (c) where the wall is supported by soft clay within its height or beneath its base.

    5 Displacement calculations shall take into account the stiffness of the ground and structural
    elements and the sequence of construction.

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    6 The effect of vibrations on displacements shall be considered with regard to the following:

    rw
    (a) Foundations for structures subjected to vibrations or to vibrating loads shall be
    designed to ensure that vibrations will not cause excessive settlements.
    (b)
    ta
    Precautions should be taken to ensure that resonance will not occur between the
    frequency of the dynamic load and a critical frequency in the foundation-ground
    qa
    system, and to ensure that liquefaction will not occur in the ground.
    (c) Vibrations caused by earthquakes shall be considered using the guidelines of the
    as

    designated section of the QCS.


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    Figure 5.1 Examples of Limit Modes for Overall Stability of Retaining Structures
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 11
    Part 05: Retaining Structures

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    Figure 5.2 Examples of Limit Modes for Foundation Failures of Gravity Walls

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    (EN 1997-1:2004+A1:2013)
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    Figure 5.3 Examples of Limit Modes for Rotational Failures of Embedded Walls
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 12
    Part 05: Retaining Structures

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    Figure 5.4 Example of a Limit Mode for Vertical Failure of Embedded Walls
    (EN 1997-1:2004+A1:2013)

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    Figure 5.5 Examples of Limit Modes for Structural Failure of Retaining Structures
    (EN 1997-1:2004+A1:2013)
    QCS 2014 Section 04: Foundations & Retaining Structures Page 13
    Part 05: Retaining Structures

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    Figure 5.6 Examples of Limit Modes for Failure by Pull-out of Anchoes
    (EN 1997-1:2004+A1:2013)

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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 01: General

    1 GENERAL------------------------------------------------------------------------------------------------------------ 2

    1.1 INTRODUCTION --------------------------------------------------------------------------------------------------- 2


    1.1.1 Scope ----------------------------------------------------------------------------------------------------------------- 2
    1.1.2 References----------------------------------------------------------------------------------------------------------- 2
    1.1.3 Definitions ------------------------------------------------------------------------------------------------------------ 3
    1.1.4 Approved Products ------------------------------------------------------------------------------------------------ 4

    1.2 IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4


    1.2.1 Approved Installers ------------------------------------------------------------------------------------------------ 4
    1.2.2 Field Quality Control ----------------------------------------------------------------------------------------------- 4
    1.2.3 Rejected materials ------------------------------------------------------------------------------------------------- 5
    1.2.4 Records --------------------------------------------------------------------------------------------------------------- 5

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    QCS 2014 Section 05: Concrete Page 2
    Part 01: General

    1 GENERAL

    1.1 INTRODUCTION

    1.1.1 Scope

    1 This Section includes the requirements for concrete work for pipelines, roadworks, runways,
    structures, water retaining structures, foundations and bases for structures and equipment.

    2 This Part includes relevant standards, definitions, abbreviations, and requirements for testing
    facilities, rejected materials, and record keeping.

    3 Related Sections are as follows:


    This Section:

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    Part 2, Aggregates

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    Part 3, Cementitious Materials

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    Part 4, Water
    Part 5, Admixtures
    Part 6, Property Requirements
    Part 7, Concrete Plants
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    Part 8, Transportation and Placing of Concrete
    Part 9, Formwork
    Part 10, Curing
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    Part 11, Reinforcement


    Part 12, Construction Joints
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    Part 13, Inspection and Testing of Hardened Concrete


    Part 14, Protective Coatings to Concrete
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    Part 15, Hot Weather Concrete


    Part 16, Miscellaneous
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    Part 17, Precast Concrete


    Part 18, Prestressed Concrete
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    Part 19, Water Retaining Structures


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    Section 1, General
    Section 2, Quality Assurance and Quality Control
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    Section 4, Foundations and Retaining Structures


    Section 6, Roadworks
    Section 8, Drainage Works
    Section 9, Mechanical and Electrical Equipment

    1.1.2 References

    1 The following standards are referred to in this Part:


    ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in
    the Field
    ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical
    Concrete Specimens
    ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete
    ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed Hydraulic-
    Cement Concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 01: General

    BS 6100, ....................Glossary of Building and civil engineering terms


    BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling
    BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing
    laboratory samples
    BS EN 12350-1 ..........Method of sampling fresh concrete in site
    BS EN 12350-2 ..........Testing fresh concrete. Slump-test
    BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds
    BS EN 12390-2 .......... Making and curing specimens for strength tests
    GSO ISO 1920-1 ........Testing of concrete Part 1: Sampling of fresh concrete
    GSO ISO 1920-2 ........Testing of concrete Part 2: Properties of fresh concrete
    GSO ISO 1920-3 ........Testing of concrete Part 3: Making and curing test specimens

    1.1.3 Definitions

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    1 Definitions used in this Section.

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    The following are terms and abbreviations used:
    C degree Celsius
    cal
    cm
    calorie
    centimetre ta
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    d day
    fck,cyl Characteristic compressive strength of concrete determined by testing cylinders
    fc,cyl Compressive strength of concrete determined by testing cylinders
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    fck,cube Characteristic compressive strength of concrete determined by testing cubes


    fc,cube Compressive strength of concrete determined by testing cubes
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    fcm Mean compressive strength of concrete


    fcm,j Mean compressive strength of concrete at the age of (j) days
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    GGBS ground granulated blast furnace slag


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    GUTS guaranteed ultimate tensile strength


    h hour
    kg kilogram
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    kJ kilojoule
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    kN kilonewton
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    l litre
    m metre
    m

    2
    m square metre
    3
    m cubic metre
    mg milligram
    min minute
    mm millimetre
    2
    mm square millimetre
    months months
    MPa mega Pascal
    kPa kilo Pascal
    MSRPC moderate sulphate resisting Portland cement
    OPC ordinary Portland cement
    PFA pulverised fuel ash
    PVC polyvinylchloride
    s second
    SF silica fume
    SRPC sulphate resisting Portland cement
    QCS 2014 Section 05: Concrete Page 4
    Part 01: General

    ton 1000 kg
    ppm part per million
    -6
    micron 10
    -6
    m 10 meter

    2 Reference to a technical society, institution, association or governmental authority is made in


    accordance with the following abbreviations.
    AASHTO American Association of State Highway and Transportation Officials
    ACI American Concrete Institute
    ASTM American Society for Testing and Materials
    AWS American Welding Society
    BS British Standard
    BSCP British Standard Code of Practice
    BSI British Standards Institution

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    C & CA Cement and Concrete Association
    CIRIA Construction Industry Research and Information Association

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    CRSI Concrete Reinforcing Steel Institute
    CS Concrete Society
    DIN Deutsches Institut fur Normung e.V.
    EN Euro Norm
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    FHWA Federal Highway Authority
    GSO GCC Standardization Organization
    ICE Institution of Civil Engineers
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    ISO International Organization for Standardization


    PCI Prestressed Concrete Institute
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    QCS Qatar Construction Specifications


    QS Qatar Standards
    er

    UK DfT United Kingdom Department for Transport


    Products
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    1.1.4 Approved Products


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    1 The contract specific documentation may identify approved products and approved or
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    prequalified manufacturers and suppliers of products used in concrete work.


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    1.2 IMPLEMENTATION

    1.2.1 Approved Installers

    1 The contract specific documentation may identify approved or prequalified providers of


    concrete construction services.

    1.2.2 Field Quality Control

    1 The Contractor shall carry out the test procedures required by this Section and any other
    tests and test procedures as directed by the Engineer from time to time. The test procedures
    shall be carried out using the facilities of an approved independent testing laboratory.

    2 Supply, storage, sampling and testing of all materials shall be the responsibility of the
    Contractor, unless the Contract specifies otherwise.
    QCS 2014 Section 05: Concrete Page 5
    Part 01: General

    3 The Engineer may also require the Contractor to take samples of materials and deliver them
    to the Central Materials Laboratory for additional tests to be carried out by the Employer.
    Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards,
    and sample sizes shall conform to the requirements shown in Table 1.1.

    4 The minimum equipment required for testing on Site is given in Table 1.2. This equipment
    shall be maintained on Site at all times during concreting operations together with the
    necessary scoops, buckets, sample containers, and other items required for sampling. The
    cube curing tank shall be located in an air-conditioned area as stated in part 06.

    1.2.3 Rejected materials

    1 Any material rejected by the Engineer, in particular cement which has deteriorated or
    aggregates which have segregated or become contaminated, shall be immediately removed
    from the Site.

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    1.2.4 Records

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    1 The Contractor shall maintain on the Site full records of all work carried out accurately
    related to the location of the work on site, which shall include:
    (a) the time and date when all concrete was poured, formwork removed and when
    formwork props were fully removed ta
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    (b) all cubes and other tests
    (c) daily maximum and minimum temperatures.
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    2 One copy of all test results shall be sent to the Engineer immediately upon completion of the
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    tests
    Table 1.1
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    Sampling Procedure and


    Minimum Sample Sizes for Central Materials Laboratory
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    Material Test Min. Sample


    Composite sample of 7 kg
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    Cement Full range of tests


    taken from at least 12 bags
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    Full range of tests 200 kg


    Sieve analysis
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    Chemical analysis
    Soundness test
    Aggregate Water absorption
    Particle density 50 kg
    Flakiness index
    Fines content
    LA Abrasion value

    Tensile test 500 mm


    Reinforcement
    Bend test 300 mm

    Water Full range of tests 5 litres


    QCS 2014 Section 05: Concrete Page 6
    Part 01: General

    Table 1.2
    Minimum Testing Equipment for Each Site*
    Minimum Number
    Test Equipment to be Provided
    Required
    Slump cone with base plate 1
    Slump test BS EN
    Compacting rod, circular cross-section 1
    12350-2
    and round ends 1
    or
    Remixing container, 300 mm ruler, 1
    GSO ISO 1920-2
    moist cloth 1
    or
    Scoop and shovel
    ASTM C143
    Timer
    Cube making 100 or 150 mm cubical or cylindrical 6
    1
    BS EN 12390-1 moulds
    and Compacting rod or bar Set of tools for 1

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    BS EN 12350-1:2000 assembling and stripping moulds

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    or Remixing container 1

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    GSO ISO 1920-1 Trowel, Scoop, Shovel and Mallet -
    and Mould release agent in closed -
    GSO ISO 1920-3 container with brush 1
    or ASTM C31 and C39
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    Hessian or sacking, impervious sheet lot
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    Cube curing BS EN Maximum/minimum thermometer 1
    12390-2 Waterproof marking crayon/paint or
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    or equivalent 1
    GSO ISO 1920-3 Curing tank (in air conditioned room) 1
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    or ASTM C39 Supply of packing materials for sending


    cubes to commercial laboratory Lot
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    ASTM C1064 Concrete thermometer 1


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    1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate
    size is not greater than 20mm
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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 10: Curing

    10 CURING .................................................................................................................. 2
    10.1 GENERAL ............................................................................................................... 2
    10.1.1 Scope 2
    10.1.2 References 2
    10.1.3 Submittals 2
    10.1.4 Quality Assurance 2
    10.1.5 Storage 2
    10.2 CURING .................................................................................................................. 2
    10.2.1 General 2
    10.2.2 Water for Curing 3
    10.2.3 General Requirements 3
    10.2.4 Curing of Formed Surfaces 4

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    10.2.5 Curing of Unformed Surfaces 4

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    10.2.6 Moisture Curing 4
    10.2.7 Moisture Retaining Cover Curing 4

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    10.2.8 Liquid Membrane Curing 5
    10.2.9 Steam Curing 5
    10.2.10 Pavements and other slab on ground
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    10.2.11 Buildings, bridges, and other structures 5
    10.2.12 Mass concrete 6
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    QCS 2014 Section 05: Concrete Page 2
    Part 10: Curing

    10 CURING

    10.1 GENERAL

    10.1.1 Scope

    1 This part covers the requirements for the curing of concrete.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, ............ General
    Part 4, ............ Water
    Part 6, ............ Property Requirements

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    Part 15, ........... Hot Weather Concreting

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    Part 16, ........... Miscellaneous.

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    10.1.2 References
    AASHTO M 148.74, ...Liquid Membrane Curing
    ACI 308 ..................... Guide to Concrete Curing
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    ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing
    Concrete
    BS 7542,..................... Method of test for curing compounds for concrete.
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    ISO 9001: 2008 Quality management systems -- Requirements


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    10.1.3 Submittals
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    1 The Contractor shall submit to the Engineer the proposed method of curing for approval.
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    10.1.4 Quality Assurance


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    1 The Contractor shall submit to the Engineer for approval the details of proposed curing
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    media, if any. Details shall include chemical tests for the product in accordance with
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    BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.
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    10.1.5 Storage

    1 Chemical curing compounds shall be stored in accordance with manufacturer's


    recommendations.

    10.2 CURING

    10.2.1 General

    1 The Contractor shall ensure that curing is provided for 24 hours per day including holidays
    and that all related necessary plant and labour resources are also available.

    2 Special attention shall be given to the curing of vertical and overhanging surfaces to ensure
    satisfactory curing.
    QCS 2014 Section 05: Concrete Page 3
    Part 10: Curing

    3 The Contractor shall adopt curing measures that preclude the possibility of thermal shock to
    the concrete during curing. This may be achieved by ensuring that the temperature of the
    water used for curing does not differ from that of the concrete by more than 15 C.

    4 Curing shall continue for at least 7 days and until it attains an in-place compressive strength
    of the concrete of at least 70% of the specified compressive or flexural strength, whichever
    period is longer. Curing shall not stop unless otherwise approved by the Engineer.

    5 When low W/cm is used, the concrete shall be preferably cured by water.

    10.2.2 Water for Curing

    1 Water used for any curing purposes shall conform to the requirements of Part 4 of this
    Section.

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    10.2.3 General Requirements

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    1 Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive
    drying out.

    2
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    All concrete shall be cured for a period of time required to obtain the full specified strength,
    but not less than seven consecutive days. The method of curing shall be by water for the first
    qa
    seven days and by water or membrane until the concrete has reached the full specified
    strength.
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    3 For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative
    se

    environments, or both, the curing shall start at early anytime between placement and final
    finishing of the concrete. The curing shall be by reducing the moisture loss from surface
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    using fogging systems and the use of evaporation reducers such as monomolecular water
    curing compound.
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    4 Exposed surfaces shall be protected from air blown contamination until 28 d after the
    concrete is placed.
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    5 The method of curing shall ensure that sufficient moisture is present to complete the
    et

    hydration of the cement, and shall be to the approval of the Engineer. The method of curing
    shall not:
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    (a) disfigure permanently exposed surfaces


    (b) affect bonding of subsequent coatings
    (c) increase the temperature of the concrete.

    6 During the curing period, exposed concrete surface shall be protected from the direct rays of
    the sun.

    7 When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water
    is present on the surface of the concrete.

    8 The applied film of the liquid membrane shall be continuous and protected from rain and any
    damages for at least 14 days.
    QCS 2014 Section 05: Concrete Page 4
    Part 10: Curing

    10.2.4 Curing of Formed Surfaces

    1 Formed surfaces, including the underside of beams, girders, supported slabs and the like, by
    moist curing with the forms in place for the full curing period, or until the forms are removed.

    2 When the forms are stripped, curing shall continue by any approved method.

    3 When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In
    such cases the concrete surface shall be prepared prior to the application of the membrane
    as recommended by the manufacturer.

    4 Water curing is not required when liquid membrane is used.

    10.2.5 Curing of Unformed Surfaces

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    1 Unformed surfaces shall be protected as soon as possible after the concrete has been

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    placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material

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    shall be placed on the concrete surface and shall be kept wet for the required period. The
    hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of
    water. Alternatively a curing method approved by the Engineer may be used.

    2 ta
    Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams
    qa
    shall be water cured and covered with wet hessian for the required curing period.
    as

    10.2.6 Moisture Curing

    1 Moisture curing shall be performed by :


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    (a) covering the surface of the concrete with water and keeping it continuously wet
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    (b) continuous use of fine fog water sprays


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    (c) covering the surface with a saturated absorptive cover and keeping it continuously
    wet.
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    (d) Burlap, cotton mats, and other absorbent materials can be used to hold water on
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    horizontal or vertical surfaces.


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    (e) Wet straw or hay can be used for wet-curing small areas, but there is the danger that
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    wind might displace it unless it is held down with screen wire, burlap, or other means

    2 Where method (a) is employed, the bunds used shall not be made from fill from excavations
    or any other areas where there is the possibility of chloride contamination.

    10.2.7 Moisture Retaining Cover Curing

    1 The concrete surface shall be covered with a suitable absorptive covering, such as wet
    hessian.

    2 The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

    3 The cover shall be in the widest practical widths and shall have 100 mm side and end laps.

    4 Any penetrations or tear in the covering shall be shall be repaired with the same material and
    waterproof tape.
    QCS 2014 Section 05: Concrete Page 5
    Part 10: Curing

    10.2.8 Liquid Membrane Curing

    1 Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM
    C 309 or C1315 when tested at the rate of coverage use on the job.

    2 ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid
    membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for
    determining the efficiency of liquid membrane-forming compounds.

    3 Membrane forming curing compounds shall be applied in accordance with the manufacturer's
    recommendations immediately after any water sheen which may develop after finishing has
    disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

    4 Membrane forming curing compounds shall not be used on surfaces against which additional
    concrete or other material is to be bonded unless:

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    (a) it is proven that the curing compound will not prevent bond, or

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    (b) positive measures are taken to remove it completely from those areas which are to
    receive bonded applications
    (c) on fair faced concrete surfaces.
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    10.2.9 Steam Curing

    1 An enclosure shall be formed around the concrete using tarpaulin or other suitable means.
    as

    2 Application of steam shall not be commenced until at least 2 h after final placement of
    se

    concrete.
    er

    3 Steam shall be applied at a temperature between 65 C and 80 C.


    ov

    4 Excessive rates of heating and cooling shall be prevented during steam curing and
    temperatures in the enclosure shall not be allowed to increase or decrease by more than
    22 C per hour.
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    5 The maximum steam temperature shall be maintained in the enclosure until concrete has
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    reached its specified strength.


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    10.2.10 Pavements and other slab on ground

    1 Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective
    measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be
    initiated immediately to reduce evaporation.

    2 Mats used for curing can either be left in place and kept saturated for completion of the
    curing, or can be subsequently replaced by a liquid membrane-forming curing compound,
    plastic sheeting, reinforced paper, straw, or water

    10.2.11 Buildings, bridges, and other structures

    1 Additional curing shall be provided after the removal of forms


    QCS 2014 Section 05: Concrete Page 6
    Part 10: Curing

    2 After the concrete has hardened and while the forms are still in place on vertical and other
    formed surfaces, form ties may be loosened when damage to the concrete will not occur and
    water applied to run down on the inside of the form to keep the concrete wet.

    3 Care shall be taken to prevent thermal shock and cracks when using water that is
    significantly cooler than the concrete surface. Curing water should not be more than about
    o
    11 C cooler than the concrete.

    4 Immediately following form removal, the surfaces shall be kept continuously wet by a water
    spray or water-saturated fabric or until the membrane-forming curing compound is applied.
    Curing

    10.2.12 Mass concrete

    1 Mass concrete is often cured with water for the additional cooling benefit in warm weather;

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    however, this can be counterproductive when the temperature gradient between the warmer

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    interior and the cooler surface generates stress in the concrete.

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    2 Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously
    wet by water spraying, wet sand, or water saturated fabrics.

    3 ta
    For vertical and other formed surfaces, after the concrete has hardened and the forms are
    qa
    still in place, the form ties may be loosened and water supplied to run down the inside of the
    form to keep the concrete wet
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    4 Care shall be taken to prevent thermal shock and cracks when using water that is
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    significantly cooler than the concrete surface. Curing water should not be more than about
    o
    11 C cooler than the concrete.
    er

    5 Curing shall start as soon as the concrete has hardened sufficiently to prevent surface
    ov

    damage.

    6 For unreinforced massive sections not containing ground granulated blast-furnace slag or
    o

    pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated
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    blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall
    et

    be not less than 3 weeks.


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    7 For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until
    70% of the specified compressive strength is obtained, if strength is the key concrete
    performance criterion. For construction joints, curing shall be continued until resumption of
    concrete placement or until the required curing period is completed.

    8 Curing shall not stop until favourable differential temperature is attained and at the approval
    of the Engineer.

    9 For mass concrete, thermocouples shall be used to monitor the temperature differential of
    the concrete.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 11: Reinforcement

    11 REINFORCEMENT ................................................................................................. 2
    11.1 GENERAL ............................................................................................................... 2
    11.1.1 Scope 2
    11.1.2 References 2
    11.1.3 Submittals 3
    11.1.4 Quality Assurance 3
    11.1.5 Delivery Storage and Handling 3
    11.2 REINFORCING MATERIALS .................................................................................. 4
    11.2.1 Reinforcing Bars 4
    11.2.2 Welded Steel Wire Fabric 4
    11.2.3 Tie Wire 5
    11.3 INSPECTION, SAMPLING AND TESTING.............................................................. 5

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    11.3.2 Sampling 5

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    11.3.3 Testing 6

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    11.4 CUTTING AND BENDING OF REINFORCEMENT ................................................. 6
    11.5 FIXING OF REINFORCEMENT ............................................................................... 6
    11.5.1
    11.5.2
    General
    Welding ta 6
    7
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    11.5.3 Mechanical Splices 8
    11.5.4 Bundling and Splicing of Bundled Bars 8
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    11.5.5 Examination 8
    11.5.6 Electrolytic Action 8
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    11.5.7 Cover 8
    11.5.8 Reinforcement 8
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    11.5.9 Forms and Linings 9


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    11.5.10 Tanking 9
    11.5.11 Adjustment and Cleaning 9
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    11.6 PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9


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    11.6.2 Epoxy Coated Reinforcing Bars 9


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    11.6.3 Handling of Epoxy Coated Reinforcement 11


    11.6.4 Testing of Epoxy Coated Reinforcement 11
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    QCS 2014 Section 05: Concrete Page 2
    Part 11: Reinforcement

    11 REINFORCEMENT

    11.1 GENERAL

    11.1.1 Scope

    1 This Part includes tension, compression, and temperature reinforcing steel, including welded
    wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and
    placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric,
    ties, and supports.

    2 Related Sections and Parts are as follows:


    This Section
    Part 16 ............. Miscellaneous

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    Part 17 ............. Structural Precast Concrete

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    11.1.2 References

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    ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for
    Prestressed Concrete

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    ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for
    qa
    Concrete Reinforcement
    ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete
    Reinforcement
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    ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or


    Low-Relaxation for Prestressed Concrete Railroad Ties
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    ASTM A882/A882M- ..Standard Specification for Filled Epoxy-Coated Seven-Wire


    Prestressing Steel Strand
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    ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars
    for Concrete Reinforcement
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    ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel
    Wire and Welded Wire for Concrete Reinforcement
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    ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for
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    Concrete Reinforcement:
    et

    BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete
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    BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of
    concrete
    BS 4483: 2005............Steel fabric for the reinforcement of concrete
    BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing
    of concrete.
    BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of
    steel reinforcement for concrete

    EN 1011, ....................Welding. Recommendation for welding of metallic materials


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

    ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete


    ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the
    reinforcement of concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 11: Reinforcement

    ISO 3766 ...................Construction drawings -- Simplified representation of concrete


    reinforcement
    ISO 9000, ..................Quality management systems. Fundamentals and vocabulary

    QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars
    QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars
    QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric

    11.1.3 Submittals

    1 Product data including the manufacturers specification and installation instructions for
    proprietary materials and reinforcement accessories shall be provided.

    2 The Contractor shall submit the manufacturers records of chemical and physical properties

    .
    of each batch of billet steel bars and a certificate that the respective material furnished meets

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    the requirements for the steel reinforcement specified. The manufacturers records shall
    include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

    rw
    3 Three copies of the steel test report shall be furnished with each consignment of steel

    ta
    reinforcement. The steel shall be tagged and cross-referenced with mill certificates.
    qa
    11.1.4 Quality Assurance

    1 The Contractor shall submit to the Engineer for source approval details of the proposed
    as

    source of supply of the reinforcement. Details shall include chemical and physical tests for
    the past six months production and any independent test results for this period. Details of
    se

    quality assurance procedures, including ISO 9000 certificate if held, shall also be given.
    er

    2 The Contractor shall furnish the Engineer with a certificate of compliance for each shipment
    of epoxy coated bars. The certificate of compliance shall state that representative samples of
    ov

    the epoxy coated bars have been tested and that the test results comply with the
    requirements herein specified. Test results shall be retained by the Contractor for seven
    o

    years. A complete set of test results shall also be handed to the client at the completion of
    reinforcement works, and shall be made available to the Engineer upon request.
    it
    et

    11.1.5 Delivery Storage and Handling


    m

    1 On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show
    the manufacturers test number and lot number and other applicable data that will identify the
    material with the certificate issued for that lot of steel. The fabricator shall furnish three
    copies of a certification which shows the batch number or numbers from which each size of
    bar in the shipment was fabricated.

    2 Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the


    ground surface to prevent damage and accumulation of dirt, rust and other deleterious
    matter. Storage facilities shall be such as to permit easy access for inspection and
    identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark
    reference.
    QCS 2014 Section 05: Concrete Page 4
    Part 11: Reinforcement

    3 The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock
    loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free
    from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may
    impair the bond between the concrete and the reinforcement. The reinforcement shall be
    covered to ensure protection from wind blown dust, condensation and other deleterious
    materials.

    11.2 REINFORCING MATERIALS

    11.2.1 Reinforcing Bars

    1 Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply
    with the requirements of:

    (i) QS ISO 6935 with minimum grade of B500 MPa or

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    (ii) BS 4449 with minimum grades of B500 MPa ; or..

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    (iii) ASTM A615 / A615M with minimum grade of 75 [520MPa]; or
    (iv) Deformed and Plain, Low-carbon-Chromium-Steel Bars for Concrete

    (v)
    Reinforcement: ASTM A1035/ A1035M
    ta
    ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain
    qa
    Stainless Steel Wire and Welded Wire for Concrete Reinforcement
    (vi) ASTM A955/A955M-14 Standard Specification for Deformed and Plain
    as

    Stainless-Steel Bars for Concrete Reinforcement


    se

    (vii) Other types of reinforcement, as approved by Qatar Standards

    2 As per project design, other steel grades of less than B500MPa may be used only for stirrups
    er

    and secondary reinforcement of diameter of 10mm or less.


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    3 If the steel has excessive surface rust, dust or other deleterious material then the steel shall
    be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of
    o

    the reinforcement or concrete. Dune sand shall not be used for the sandblasting of
    it

    reinforcement.
    et

    4 For extreme exposure class X5; protection measures such as epoxy coated bars; Low-
    m

    carbon-chromium-steel bars; or Stainless Steel may be considered.

    11.2.2 Welded Steel Wire Fabric

    1 Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483
    and shall be delivered to Site in flat mats.

    2 Welded intersections shall not be spaced more than:

    (a) 300 mm for plain round bars


    (b) 400 mm apart for deformed high yield bars in direction of calculated stress except
    when used as stirrups.
    QCS 2014 Section 05: Concrete Page 5
    Part 11: Reinforcement

    11.2.3 Tie Wire

    1 Tie wire shall conform to the requirements of BS 4482.

    2 1.6 mm black annealed mild steel shall be used for tie wire.

    3 No wires smaller than size D-4 shall be used.

    11.3 INSPECTION, SAMPLING AND TESTING

    1 Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.

    2 The Contractor shall give 24 hour notice to the Engineer before closing forms or placing

    .
    concrete.

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    3 The Engineer may instruct the Contractor to break out and remove completely all sections of

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    the work already constructed under any of the following circumstances:

    (a) reinforcing steel sample under test fails to meet the specification requirements at any
    time
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    qa
    (b) the Engineer considers that samples which were presented to him for test were not
    truly representative
    as

    (c) a previously rejected reinforcing steel has been used in the Works.
    se

    11.3.2 Sampling

    1 Representative samples of all reinforcing steel proposed for use in the Works must be
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    submitted by the Contractor, before work is commenced, to the Engineer for his written
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    approval.

    2 Manufacturer's certificates stating clearly for each sample:


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    (a) place of manufacture


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    (b) expected date and size of deliveries to site


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    (c) all relevant details of composition, manufacture, strengths and other quality of the
    steel.

    3 The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at
    the work site.

    4 Frequency of sampling and the method of quality control shall be in accordance with steel
    bars manufactured standard QS ISO 6935 or BS 4449 .

    5 Where epoxy coated steel is used, a sample of the coating material shall be supplied with
    each batch in an airtight container and identified by the batch number.

    6 Allow 14 days for Engineers review of samples.


    QCS 2014 Section 05: Concrete Page 6
    Part 11: Reinforcement

    11.3.3 Testing

    1 Tests shall be carried out when directed by the Engineer.

    2 Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.

    3 The following information shall be provided with each delivery of reinforcement:

    (a) elastic limit


    (b) ultimate strength
    (c) stress/strain curve
    (d) cross-sectional area
    (e) deformation/bond characteristics of deformed bars.

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    4 The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or
    rebend tests at own cost, for each size of bar to be used in the concrete construction.

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    5 Test results for each bar size shall be submitted to the Engineer three weeks before concrete
    work commences on Site.
    ta
    qa
    6 Full testing shall be required if the source of supply of reinforcement changes, in which case
    the cost of such extra testing will be borne by the Contractor.
    as

    7 When any test results do not conform to the relevant standard the reinforcement steel shall
    be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.
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    11.4 CUTTING AND BENDING OF REINFORCEMENT


    er

    1 Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and
    ov

    shall be done without the application of heat. Bends shall have a substantially constant
    curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply
    o

    2 Steel bars manufactured according to the approved ASTM standards shall be bent according
    it

    to the same standard.


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    3 Reinforcement shall not be straightened or rebent without the approval of the Engineer. If
    permission is given to bend projecting reinforcement care shall be taken not to damage the
    concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or
    BS 8666.

    11.5 FIXING OF REINFORCEMENT

    11.5.1 General

    1 All reinforcement shall be securely and accurately fixed in positions shown on the Drawings
    to ensure that the reinforcement steel framework as a whole shall retain its shape. The
    framework shall be supported to retain its correct position in the forms during the process of
    placing and consolidating the concrete.

    2 The ends of all tying wires shall be turned into the main body of the concrete and not allowed
    to project towards the surface.
    QCS 2014 Section 05: Concrete Page 7
    Part 11: Reinforcement

    3 No part of the reinforcement shall be used to support access ways, working platform or for
    the conducting of an electric current.

    4 The Contractors specific attention is drawn to the following general requirements:

    (a) lapped joints shall be as indicated on the Drawings and/or in accordance with the
    requirements of EN 1992-1-1 or BS 8666
    (b) hooks shall be semicircular with a straight length of at least:
    (i) four bar diameters for mild steel
    (ii) six bar diameters for high yield steel.

    11.5.2 Welding

    1 Welding shall not be used unless authorised by the Engineer and recommended by the

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    reinforcement manufacturer.

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    2 Where welding is approved it shall be executed under controlled conditions in a factory or
    workshop.

    3
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    Welding shall not take place on site without the approval of the Engineer and unless suitable
    safeguards and techniques are employed and the types of steel employed have the required
    qa
    welding properties.
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    4 Welding if approved, may be used for:

    (a) fixing crossing or lapping reinforcement in position


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    (b) fixing bars to other steel members


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    (c) structural welds involving transfer of loads between reinforcement or between bars
    and other steel members.
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    5 The length of run deposited in a single pass shall not exceed five times the bar diameter. If a
    longer welded length is required, the weld shall be divided into sections with the space
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    between runs made not less than five times the bar diameter.
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    et

    6 Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be
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    approved, subject to their satisfactory performance in trial joints.

    7 Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for
    lapped joints.

    8 Flash butt welding shall be executed with the correct combination of flashing, heating,
    upsetting and annealing, using only machines which automatically control this cycle of
    operations.

    9 Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement
    manufacturer.

    10 Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of
    principle reinforcement shall be staggered, unless otherwise approved. The distance
    between staggered joints shall be not less than the end anchorage length joints.

    11 Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.
    QCS 2014 Section 05: Concrete Page 8
    Part 11: Reinforcement

    11.5.3 Mechanical Splices

    1 Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and
    where indicated on the Drawings.

    2 Details of mechanical splices shall be submitted to the Engineer for approval.

    11.5.4 Bundling and Splicing of Bundled Bars

    1 Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.

    2 Splicing, except where indicated on the Drawings or approved shop drawings, will not be
    permitted without the approval of the Engineer.

    11.5.5 Examination

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    1 The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of

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    reinforcement in order to facilitate the inspection of formwork.

    2 The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.

    11.5.6 Electrolytic Action ta


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    1 Reinforcement shall not be fixed or placed in contact with non-ferrous metals.
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    11.5.7 Cover
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    1 Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer
    pieces.
    er

    2 The cover shall not be less than given in Section 5 Part 6.


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    3 Spacers, chairs and other supports shall be provided as necessary to maintain the
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    reinforcement in its correct position.


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    et

    4 In a member where the nominal cover is dimensioned to the links, spacers between the links
    and formwork shall be the same dimension as the nominal cover.
    m

    5 Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in
    diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars
    are detailed.

    6 Spacers, chairs and other supports shall be made of concrete, plastic or other material to the
    approval of the Engineer. Where supports are made of concrete they shall have at least the
    same cube strength as the concrete in the host member.

    11.5.8 Reinforcement

    1 Placing of all reinforcement steel bars will be checked by the Engineer and in no case is
    concrete to be placed around any reinforcement steel that has not been approved by the
    Engineer. Insertion of bars into or the removal of bars from concrete already placed will not
    be permitted.
    QCS 2014 Section 05: Concrete Page 9
    Part 11: Reinforcement

    2 Reinforcement steel temporarily left projecting from the concrete at the joints shall not be
    bent without the prior approval of the Engineer.

    11.5.9 Forms and Linings

    1 Damage to forms and linings shall be avoided.

    11.5.10 Tanking

    1 Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.

    11.5.11 Adjustment and Cleaning

    1 Check position of reinforcement before and during placing concrete:

    .
    (a) pay particular attention to the position of top reinforcement in cantilever sections

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    (b) ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill

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    scale, oil and other substances which may adversely affect reinforcement, concrete, or
    the bond between the two.

    2
    ta
    Protect projecting reinforcement from the weather where rust staining of exposed concrete
    surfaces may occur.
    qa
    3 At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and
    as

    freed from all mud, oil or any other coatings that might destroy or reduce the bond:

    (a) clean all set or partially set concrete which may have been deposited thereon during
    se

    the placing of a previous lift of concrete


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    (b) all uncoated rust bars shall be again sand blasted and pressure washed.
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    4 Immediately before concrete placing the reinforcing steel shall be washed thoroughly with
    high pressure potable water jets to remove any deposited salts.
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    11.6 PROTECTIVE COATINGS TO REINFORCEMENT


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    et

    1 All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.
    m

    11.6.2 Epoxy Coated Reinforcing Bars

    1 Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting,
    rust, grease, oil and other surface defects detrimental to proper coating.

    2 The surface shall be prepared in accordance with ISO 14654.

    3 Coating shall be applied to the cleaned surface as soon as possible after cleaning and before
    any visible oxidation to the surface occurs.

    4 Reinforcing steel shall not have surface defects that would be detrimental to coating.

    5 Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for
    coating of reinforcing bars and as follows:

    (a) epoxy resin powders which do not meet the above requirements must be tested by an
    approved independent testing laboratory and accepted by the Engineer before use
    QCS 2014 Section 05: Concrete Page 10
    Part 11: Reinforcement

    (b) only fusion bonded epoxy-coated reinforcing steel will be accepted


    (c) no other means of epoxy coating will be approved.

    6 Patching material shall be:

    (a) furnished by the epoxy coating manufacturer


    (b) compatible with the coating
    (c) inert in concrete
    (d) suitable for repairs to the coated reinforcing bars to be made by the coating applicator
    and the Contractor at the project site.

    7 Fabrication shall be performed before coating except as hereinafter specified for bent bars
    and straight bars less than 7.6 m long.

    l.
    8 Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that

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    satisfactory results can be obtained by coating before bending.

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    9 Any visible cracks in the coating on the outside of the bend or damage to coating resulting in
    debonding of the coating after bending shall be rejected.

    10 ta
    Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:
    qa
    (a) end damage to coating does not extend more than 12 mm back
    as

    (b) cut end is patched before any visible oxidation appears.


    se

    11 Flame cutting will not be permitted.

    12 Epoxy coating shall be checked visually after cure for continuity of coating and shall be free
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    from holes, contamination, cracks and damaged areas.


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    13 There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm
    of the epoxy coated bar.
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    14 A holiday detector shall be used in accordance with the manufacturer's instruction to check
    et

    the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or
    its approved equivalent shall be used.
    m

    15 Patching of holidays is not required if there are less than three holidays per 300 mm length.
    Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced
    as directed by the Engineer.

    16 Epoxy coating film shall be cured and/or post cured to a fully cured condition. A
    representative proportion of each production lot shall be checked by the epoxy coating
    applicator, using the method most effective for measuring cure to ensure that the entire
    production lot of epoxy coating is supplied in the fully cured condition.

    17 Contractor shall repair all coating damaged by fixtures used to handle or support the bars in
    the coating process as follows:

    (a) patching shall be done as soon as possible and before visible oxidation occurs
    (b) excessive patching from other causes will not be permitted
    QCS 2014 Section 05: Concrete Page 11
    Part 11: Reinforcement

    (c) satisfactory correction shall consist of proper adjustment of process, and rerunning
    the bars through the plant.

    18 The Engineer reserves the right for access to the epoxy coating applicators plant to witness
    epoxy coating processes for project work and to obtain specimens from test bars for any
    testing desired.

    19 All chairs, tie wires and other devices used in connecting, supporting, securing or fastening
    epoxy coated reinforcement steel shall be made of or coated with a dielectric material.

    20 Before the reinforcement is lowered into place and before placement of the concrete, the
    coated bars shall be inspected by the Engineer for damage to the epoxy coating.

    21 Sheared ends of bars and other areas requiring limited repair due to scars and minor defects
    shall be repaired, using the specified patching or repair materials.

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    11.6.3 Handling of Epoxy Coated Reinforcement

    rw
    1 Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars
    or, where used, the epoxy coating.

    2 ta
    Bars, or where used epoxy coating, damaged in handling or other operations shall be
    qa
    satisfactorily repaired at no additional cost to the Employer.

    3 Where epoxy coated bars are used all handling systems shall have plastic mandrel and
    as

    padded contact areas wherever possible.


    se

    4 Where epoxy coated bars are used all bundling bands shall be padded.
    er

    5 All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to
    prevent bar to bar abrasion from sags in the bar bundle.
    ov

    6 Bars or bundles shall not be dropped or dragged.


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    7 During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not
    it

    damaged by the pokers.


    et
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    11.6.4 Testing of Epoxy Coated Reinforcement

    1 Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each
    production lot.

    2 At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be
    furnished as test bars.

    3 Test bars may be in one length or multiple lengths as required to have one test bar of each
    size with each production lot.

    4 The production epoxy coated test bars shall be evaluated by bending 120 (after rebound)
    around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.
    QCS 2014 Section 05: Concrete Page 12
    Part 11: Reinforcement

    Table 11.1
    Mandrel Diameter for Bar Diameter for
    Evaluation Test of Epoxy Coated Test Bars
    Bar Diameter Diameter of Mandrel
    (mm) (mm)

    10 79
    12 95
    13 103
    14 111
    16 127
    18 143
    20 159
    22 175

    .
    24 191

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    25 198
    26 206

    rw
    28 222
    30 238
    32
    34 ta 254
    270
    qa
    36 286
    as

    5 Bend shall be made at a uniform rate and may take up to one minute to complete.
    se

    6 Bend test shall be conducted at a room temperature of between 20 C and 30 C after the
    er

    specimen has been exposed to room temperature for a sufficient time to ensure that it has
    reached thermal equilibrium.
    ov

    7 No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the
    bent bar.
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    et

    END OF PART
    m
    QCS 2014 Section 05: Concrete Page 1
    Part 12: Joints

    12 JOINTS.................................................................................................................... 2
    12.1 GENERAL ............................................................................................................... 2
    12.1.1 Scope 2
    12.1.2 References 2
    12.1.3 Submittals 2
    12.1.4 Quality Assurance 3
    12.1.5 Definitions 3
    12.2 CONSTRUCTION JOINTS ...................................................................................... 4
    12.2.1 General 4
    12.2.2 Construction Joints in Water Retaining Structures 4
    12.3 MOVEMENT JOINTS .............................................................................................. 5
    12.3.1 General 5

    .
    12.3.2 Joint Filler 6

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    12.3.3 Joint Sealants 6

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    12.4 SLIP BEARINGS ..................................................................................................... 7
    12.4.1 General 7
    12.5
    12.5.1 General ta
    WATERSTOPS ....................................................................................................... 7
    7
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    12.5.2 Waterstops 7
    12.5.3 Butyl Rubber Waterstops 8
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    12.5.4 Water Swelling Gaskets 8


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    et
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    QCS 2014 Section 05: Concrete Page 2
    Part 12: Joints

    12 JOINTS

    12.1 GENERAL

    12.1.1 Scope

    1 This part deals with movement and construction joints, slip bearings, waterstops and
    associated sealants and filler materials.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1 ............... General
    Part 10, ............ Curing

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    Part 15, ............ Hot Weather Concreting

    .l.
    Part 16, ............ Miscellaneous

    rw
    12.1.2 References
    ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for

    ta
    Concrete Paving and Structural Construction (Non-extruding and
    qa
    Resilient Bituminous Types)
    ASTM D2240 ..............Standard Test Method for Rubber PropertyDurometer Hardness
    ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From
    as

    Olefin Polymers
    se

    BS 903........................Physical testing of rubber


    er

    BS 2571......................General purpose flexible PVC compounds for moulding and extrusion


    BS 2782,.....................Methods of testing plastics
    ov

    BS 6093,.....................Design of joints and joining in building construction


    BS 7164,.....................Chemical tests for raw and vulcanized rubber
    o

    BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and


    it

    containing structures
    et

    BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test


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    CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop

    ISO 9001 ....................Quality management systems. Requirements

    12.1.3 Submittals

    1 The Contractor shall submit for approval by the Engineer as soon as practicable after
    acceptance of his Tender and not less than three weeks before commencement of
    concreting, drawings showing his proposals for the position of construction joints having due
    regard to any that may be shown on the Contract Drawings.
    QCS 2014 Section 05: Concrete Page 3
    Part 12: Joints

    2 For slide bearings the Contractor shall provide at least three samples of the proposed
    material, together with the manufacturer's technical specifications and recommendations in
    respect of application and performance.

    3 For slip joints the Contractor shall provide at least three samples of materials proposed,
    together with manufacturer's technical specifications and recommendations in respect of
    application and performance.

    4 For waterstops the Contractor shall provide at least three samples of proposed types,
    including prefabricated joints and junctions, if applicable. If joints are to be made up on site,
    provide worked samples, including samples for each make of waterstop, where samples
    from different manufacturers are provided.

    5 The Contractor must supply a certificate of compliance for the joint sealant, stating that it
    meets the requirements of the specification. The Contractor shall also supply the

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    Manufacturers technical and installation data for the proposed material. The Contractor shall

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    provide details of previous installations of the product, with the client name, structure name,

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    type of joint and value of contract.

    6 The Contractor shall prepare shop drawings that show the layout of the waterstops, specials
    and joints.
    ta
    qa
    12.1.4 Quality Assurance
    as

    1 The joint sealant, including primers and debonding materials shall be compatible with each
    other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality
    se

    Assurance Scheme.
    er

    12.1.5 Definitions
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    1 Construction Joint: The surface where two successive placements of concrete meet, across
    which it is desirable to develop and maintain bond between the two concrete placements, and
    through which any reinforcement which may be present is not interrupted.
    it o

    2 Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a


    et

    weakened plane and regulate the location of cracking resulting from the dimensional change
    of different parts of the structure. (See also Isolation Joint.)
    m

    3 Expansion Joint: A separation between adjoining parts of a concrete structure which is


    provided to allow small relative movements such as those caused by thermal changes to
    occur independently.

    4 Isolation Joint: A separation between adjoining parts of a concrete structure provided to


    isolate and element and thus allow independent movement.

    5 Joints Fillers: Materials that are used to fill space within movement joints during construction.
    They may provide support to a sealant applied subsequently.
    QCS 2014 Section 05: Concrete Page 4
    Part 12: Joints

    12.2 CONSTRUCTION JOINTS

    12.2.1 General

    1 Where construction joints are required in slabs or beams (designed by Direct Design Method
    DDM) they shall be located within the middle third of their spans, and at one-third to one-
    quarter of span in slabs and beams subject to a maximum spacing of approximately 9
    metres. Where slabs are supported by beams then the beams and slabs shall be constructed
    in one operation.

    2 In all cases vertical stop boards of a form to be approved by the Engineer shall be provided
    by at the end of each section of work which is to be concreted in one operation and the
    concrete shall be thoroughly compacted against these stop boards.

    .
    3 Where slabs, beams and walls incorporate construction joints, panels shall generally be

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    constructed consecutively. Where this is not possible a gap not exceeding one metre shall be
    formed between adjacent panels. This gap shall not be concreted until a minimum interval of

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    7 d has expired since the casting of the most recent panel.

    4 The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but

    ta
    in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with
    qa
    nominal reinforcement.

    5 Horizontal construction joints in walls will only be permitted when the wall is continuous with
    as

    the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls
    meeting the soffits of suspended members.
    se

    6 Construction joints in monolithic structures shall be aligned with each other whenever
    er

    practicable.
    ov

    7 Before placing new concrete against concrete which has already set the latter shall be
    treated to expose the aggregate over the full section and leave a sound irregular surface.
    This shall be done while the concrete is still fresh by means of water spray and light brushing
    o

    or other means approved by the Engineer.


    it
    et

    8 Immediately before the new concrete is placed all foreign matter shall be cleaned away and
    m

    the surface moistened.

    9 If during the course of the Contract it should become apparent that the Contractors methods
    of forming construction joints are not proving effective the Engineer may order the Contractor
    to execute at the Contractors expense such preventative measures as the Engineer may
    consider necessary to ensure the watertightness of the construction joints in further work.

    12.2.2 Construction Joints in Water Retaining Structures

    1 The floor may be designed as fully restrained against shrinkage and thermal contraction and
    should be cast directly onto the blinding concrete.

    2 In large structures, the floor shall be designed as a series of continuous strips with transverse
    induced contraction joints provided to ensure that cracking occurs in predetermined
    positions. Longitudinal joints between the strips should form contraction joints.
    QCS 2014 Section 05: Concrete Page 5
    Part 12: Joints

    3 Waterstops shall be incorporated into construction joints, crack induced joints, contraction
    joints and expansion joints in water retaining structures. The Contractor shall ensure that all
    such joints are watertight and any joints which may leak or weep shall be rectified by the
    Contractor to the Engineers satisfaction.

    4 The spacing of construction joints, crack induced joints, contraction joints and expansion
    joints in water retaining structures shall be shown on the design drawings.

    5 Where the positions or type of joints are not indicated on the drawings, the spacing of
    construction joints or crack induced joints in water retaining structures shall not exceed 5 m.

    6 Where the positions or type of joints are not indicated on the drawings in the ground floor
    slab, construction joints, crack induced joints, contraction joints and expansion joints shall be
    incorporated into the works as appropriate. for slabs on grade, construction joints or crack
    induced joints should be provided at areas where differences in subgrade and slab support

    l .
    may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the

    .l.
    width of the building. Within each strip for both directions, crack induced joints shall be

    rw
    provided at areas where cracks are expected and not more than 5.0 metre spacing, and
    construction or contraction joints shall be provided at not more than 15.0m spacing.

    7
    ta
    Construction or contraction joints shall be provided between adjacent strips.
    qa
    8 Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The
    waterstop should be made of a high quality material, which must retain its resilience through
    as

    the service life of the structure for the double function of movement and sealing. The surface
    of waterstops should be carefully rounded to ensure tightness of the joint even under heavy
    se

    water pressure. To ensure a good tightness with or without movement of the joints, the
    waterstop should be provided with anchor parts. The cross-section of the waterstops should
    er

    be determined in accordance with the presumed maximum water pressure and joint
    movements. The complete works of fixed and welded connections must be carried out
    ov

    strictly in accordance with the manufacturers instructions.

    9 Engineers acceptance shall be obtained by the Contractor, prior to start of work, on the
    o

    casting sequence and the layout of joints.


    it
    et

    12.3 MOVEMENT JOINTS


    m

    12.3.1 General

    1 Movement joints for expansion and contraction shall be constructed in accordance with the
    details and to the dimension shown on the Drawings or where otherwise ordered by the
    Engineer and shall be formed of the elements specified.

    2 Movement Joints in Water Retaining Structures shall be in accordance with the details and to
    the dimension shown on the Drawings and EN 1992-3.

    3 The Contractor shall pay particular attention to the effects of climatic extremes on any
    material which he may desire to use on any movement joint and shall submit for approval by
    the Engineer his proposals for the proper storage, handling and use of the said materials
    having due regard for any recommendations made by the manufacturer in this connection.
    QCS 2014 Section 05: Concrete Page 6
    Part 12: Joints

    12.3.2 Joint Filler

    1 Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if
    they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or
    equivalent if they are polymer foam type.

    2 The joint filler shall be fixed to the required dimensions of the joint cross-section and shall
    provide a firm base for the joint sealer.

    3 When required between two concrete surfaces as a resilient movement joint, the filler shall
    be an approved granulated cork bound with insoluble synthetic resin.

    4 When required between blockwork and concrete as a low density movement joint filler or for
    building details it shall be an approved bitumen impregnated fibreboard or preformed closed
    cell polyethylene.

    l .
    .l.
    12.3.3 Joint Sealants

    rw
    1 All joints to be sealed shall be formed and the groove grit blasted to remove all traces of
    deleterious materials such as form oil or curing compounds and also to remove any surface

    ta
    laitance from the sides of the joint. The joint shall be dry prior the application of priming.
    Where the use of grit blasting is not possible the Contractor may propose alternative
    qa
    methods subject to the approval of the Engineer.
    as

    2 The back of the joint shall receive a debonding tape or polyethylene foam backer cord in
    order to provide the correct depth to width ratio and prevent three sided adhesion.
    se

    3 The areas adjacent to the joint shall be protected using masking tape.
    er

    4 The sides of the joint shall be primed with the relevant primer as recommended by the
    ov

    sealant manufacturer and the sealant material applied in accordance with the manufacturers
    instructions.
    o

    5 The sealant material shall be a non-biodegradable multicomponent pitch polyurethane


    it

    elastomeric joint sealant, carefully selected as appropriate for the specific climatic and
    et

    environmental exposure conditions expected. Alternative types of sealant will be considered,


    including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the
    m

    specification and the approval of the Engineer.

    6 Where the joint sealant is to be in contact with a protective coating the Contractor shall
    satisfy the Engineer that the sealant and protective coating are compatible

    7 Sealants shall exhibit the following properties:

    (a) Movement accommodation factor 25 %


    (b) Shore A hardness 20 - 25
    (c) Solids content 100 %
    o o
    (d) Service temperature range 0 C to 90 C
    (e) Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis
    (f) Width to depth ratio 2:1
    QCS 2014 Section 05: Concrete Page 7
    Part 12: Joints

    8 Where shown on the Drawings sealants shall also be suitable for use with potable water.

    9 All surface preparation, priming, mixing and application shall be carried out in strict
    accordance with the manufacturers instructions.

    10 The sealant shall have a proven track record of no less than ten years under similar local
    conditions.

    12.4 SLIP BEARINGS

    12.4.1 General

    1 Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.

    2 They shall be extruded from specially formulated polyethylene to form a durable lamina

    l .
    resistant to sewage, mineral acids and alkalis, solvents and weathering.

    .l.
    rw
    3 Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with
    a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall
    be clean and free from deleterious materials such as form oil or curing compounds and

    ta
    surface laitance. The surface shall be level and even along the full length of the joint
    qa
    4 The applied loads for slip bearings shall not exceed 0.7 MPa.
    as

    5 Operating temperatures shall be up to 80 C


    se

    6 The coefficient of friction shall not exceed 0.15


    er

    12.5 WATERSTOPS
    ov

    12.5.1 General

    1 Waterstops and associated materials shall be by a manufacturer with a minimum of ten years
    o

    experience in the field of engineering waterproof products.


    it
    et

    2 PVC waterstops shall be suitable for storage, handling, installation and service within a range
    of 15 C to 65 C.
    m

    12.5.2 Waterstops

    1 The waterstop shall be a high performance system forming a continuous network as shown
    on the Drawings.

    2 Site jointing is to be limited to butt joints and shall be performed strictly in accordance with
    the manufacturers instructions.

    3 Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web
    sections.

    4 Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The
    water bar used at the location of expansion joints shall have a bulb in the centre to
    accommodate the movements.
    QCS 2014 Section 05: Concrete Page 8
    Part 12: Joints

    5 Waterstops shall have a minimum thickness of 3 mm.

    6 The minimum test performance data for PVC waterstops shall be as follows:
    Tensile strength >12 MPa
    Elongation at break 300 %
    Hardness Shore A 80 to 90
    7 The materials shall be tested in accordance with BS 2571 or BS 2782 or CRDC572 or
    ASTM D2240.

    12.5.3 Butyl Rubber Waterstops

    1 Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in
    accordance with BS 903.

    .
    Table 12.1

    l
    .l.
    Properties Requirements of Butyl Rubber Waterstops

    rw
    BS 903 Property Requirements

    ta
    3
    Part A1 Density 1100 kg/m ( 5 %)
    Part A26 Handness 60-70 IRHD
    qa
    2
    Part A2 Tensile Strength Not less than 17.5 N/mm
    Part A2 Elongation at break point Not less than 450 %
    as

    Part A/6 Water Absosption (48 hours immersion) Not exceeding 5 %


    se

    2 Butyl rubber waterstops shall be suitable for storage, handling, installation and service within
    a temperature of 0 C to 40 C
    er

    12.5.4 Water Swelling Gaskets


    ov

    1 Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer
    modified chloroprene rubber strips. The rubber strips shall conform to the following properties
    o

    as applicable:
    it
    et

    (a) Water pressure resistance : 5 Bar (50 m)


    m

    (b) Expansion in contact with water : 2 x original SRE


    (c) : Reversible
    (d) Application Temperatures : - 30 to + 70 C

    2 The selected rubber strips shall be available for three exposures:

    (a) Fresh Water


    (b) Seawater
    (c) Chemicals (if the condition demands or upon the Engineers request)
    The supplier shall furnish references upon request of the Engineer.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 13: Inspection and Testing of Hardened Concrete

    13 INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2


    13.1 GENERAL ............................................................................................................... 2
    13.1.1 Scope 2
    13.1.2 References 2
    13.1.3 Submittals 2
    13.1.4 Quality Assurance 3
    13.1.5 Non-Compliance of Work 3
    13.1.6 General Fieldwork Requirements 4
    13.2 CONCRETE CORES ............................................................................................... 4
    13.2.1 General 4
    13.2.2 Drilling Cores 5
    13.2.3 Testing for Strength 6

    .
    13.2.4 Assessment of Strength 7

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    13.3 REINFORCEMENT COVER MEASUREMENTS ..................................................... 7

    rw
    13.4 ULTRASONIC PULSE MEASUREMENTS .............................................................. 8
    13.4.1 General 8
    13.4.2
    13.4.3
    Selection of Test Locations
    Execution of Tests ta 8
    8
    qa
    13.4.4 Estimated In-Situ Cube Strength 9
    13.5 RADIOGRAPHY OF CONCRETE ........................................................................... 9
    as

    13.6 SURFACE HARDNESS ........................................................................................... 9


    13.6.1 General 9
    se

    13.6.2 Method of Test 9


    13.6.3 Equipment 10
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    13.6.4 Reporting 10
    ov

    13.7 CHEMICAL CONTENT .......................................................................................... 10


    13.7.1 Sampling 10
    o

    13.7.2 Laboratory Testing 11


    it
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 13: Inspection and Testing of Hardened Concrete

    13 INSPECTION AND TESTING OF HARDENED CONCRETE

    13.1 GENERAL

    13.1.1 Scope

    1 This Part of the specification covers the inspection, sampling and testing of hardened
    concrete.

    2 Related Section and Parts are as follows:

    This Section
    Part 6 ............... Property Requirements

    .
    13.1.2 References

    l
    .l.
    1 The following standards are referred to in this part of the specification:

    rw
    ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength
    Results

    ta
    ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and
    qa
    Commentary
    ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and
    Sawed Beams of Concrete
    as

    ASTM C823 ................Standard Practice for Examination and Sampling of Hardened


    Concrete in Constructions
    se

    BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete


    er

    BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic


    covermeters
    ov

    BS EN 12350..............Testing fresh concrete


    BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and
    o

    testing in compression
    it

    BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number


    et

    BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force


    m

    BS EN 12504-4 ..........Determination of ultrasonic pulse velocity


    BS EN 13791..............Assessment of in-situ compressive strength in structures and precast
    concrete components
    GSO ISO 1920-6 ........ Testing of concrete part 6: sampling, preparing and testing of
    concrete core .

    13.1.3 Submittals

    1 The Contractor shall submit to the Engineer his quality assurance procedures for the
    particular parts of the testing work that will be carried out.

    2 The Contractor shall submit for the Engineers approval the curriculum vitae (CV) of the
    supervisor proposed for the work.
    QCS 2014 Section 05: Concrete Page 3
    Part 13: Inspection and Testing of Hardened Concrete

    3 The Contractor shall through testing agency prepare a factual report that identifies the test
    methods used and the test results. The report shall also identify any unusual results or
    pertinent information relating to the testing. The report shall be presented in hard and
    electronic copies.

    4 For each of the test results the Contractor shall identify the precision or repeatability of the
    particular sampling and testing method. This shall be as given from experience of the
    particular test by the laboratory or as expected from information in the particular test
    standard.

    5 In-place tests will be valid only if the tests have been conducted using properly calibrated
    equipment in accordance with recognized standard procedures and acceptable correlation
    between test results and concrete compressive strength has been established and is
    submitted.

    l .
    6 Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete,

    .l.
    but they may be used to evaluate concrete when the standard-cured strengths fail to meet

    rw
    the specified strength criteria

    13.1.4 Quality Assurance

    1 ta
    All field and laboratory testing of concrete shall be carried out by an independent laboratory
    qa
    approved by the Engineer.
    as

    2 The evaluation of concrete in structure is needed when an existing structure is to be modified


    or redesigned; to assess structural adequacy when doubt arises about the compressive
    se

    strength in the structure due to defective workmanship, deterioration of concrete due to fire or
    other causes;when an assessment of the in-situ concrete strength is needed during
    er

    construction; to assess structural adequacy in the case of non-conformity of the compressive


    strength obtained from standard test specimens; assessment of conformity of the in-situ
    ov

    concrete compressive strength when specified in a specification or product standard.

    13.1.5 Non-Compliance of Work


    it o

    1 If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum
    et

    criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the
    m

    concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.

    2 The parts or elements of the structure made from the defective batch or batches of concrete
    as represented by the works test cubes shall be identified by the Engineer and based on this
    information the Engineer shall instruct the Contractor on the required number and position of
    concrete cores.

    3 The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or
    ACI 318 whichever is applicable to the structural design.

    4 Based on this assessment the Engineer shall decide the acceptability of the concrete in the
    structural element and may either:

    (a) accept the concrete


    (b) instruct that certain remedial works are carried out
    (c) instruct that the element is replaced.
    QCS 2014 Section 05: Concrete Page 4
    Part 13: Inspection and Testing of Hardened Concrete

    13.1.6 General Fieldwork Requirements

    1 The Contractor shall make all arrangements to provide safe stable access to testing
    locations.

    2 When gaining access to testing locations and whilst testing the Contractor shall take care not
    to damage the structure or leave it in an untidy or unclean state.

    3 The Contractor shall take precautions to ensure that cooling water from concrete coring/other
    operations is discharged such as not to cause a mess or damage the interior or exterior parts
    of the structure.

    4 The Contractor shall be responsible for arranging the water supply required for testing.

    5 The Contractor shall arrange for a suitable power supplies. Where testing is being carried out

    l .
    on an occupied structure a power supply from the building services may not available and the

    .l.
    Contractor shall make arrangements for power supply and extension leads of adequate

    rw
    length.

    6 The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field

    ta
    work. The supervisor shall have not less than five years experience of such work.
    qa
    7 Before starting the work, the Engineer with the Contractors supervisor will mark the positions
    where field testing is to be carried out. A unique referencing system to identify each sample
    as

    or testing location will be adopted, and this will either be referenced on sketch plans or
    drawings or by a detailed description used throughout the report to identify test locations.
    se

    8 If testing is being carried out on an occupied structure the Contractor shall co-ordinate with
    the owner or operator of the structure to arrange the detailed programme for the works and
    er

    gain access to the various parts of the structure.


    ov

    9 As soon as laboratory test results are available these shall be submitted by hand or faxed to
    the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing
    o

    agency, assigned by the contractor shall provide a technical report providing visual
    it

    information and analysing the tests conducted.


    et

    10 All core holes, dust sample holes and exploratory investigation areas shall be reinstated with
    m

    a proprietary non shrink cementitious repair mortar. The preparation of the hole or area
    before reinstatement shall be carried out as per the recommendation of the repair mortar
    supplier.

    11 Before filling any core holes, dust sample holes or exploratory investigation areas, the
    Contractor shall allow the Engineer time to inspect these areas and obtain written
    confirmation from the Engineer before filling.

    13.2 CONCRETE CORES

    13.2.1 General

    1 The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS
    EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the
    structural design.
    QCS 2014 Section 05: Concrete Page 5
    Part 13: Inspection and Testing of Hardened Concrete

    2 All of the supplementary information listed by the relevant standards shall be included in the
    test report with photographs of the cores.

    3 An assessment of in-situ compressive strength for a particular test region shall be based on
    at least 3 cores. Consideration shall be given to any structural implications resulting from
    taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation
    unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.

    4 The preferred minimum core diameter is three times the nominal maximum size of the
    coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse
    aggregate

    5 The Engineer will advise the required number and locations of cores. If the results of the
    initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain
    locations.

    l .
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    6 Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not

    rw
    cut through any reinforcing steel. The required diameter and depth of concrete cores shall be
    as stated in table 13.1

    Table 13.1
    ta
    qa
    1
    Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823)
    as

    Thickness of Minimum Depth to Be


    Types of Construction
    Section, m Sampled, m
    se

    Slabs, pavements, walls, linings, foundations, 0.3 or less entire depth


    structural elements accessible from one side 0.3 or greater 0.3
    er

    only
    2
    Suspended slabs , walls, conduits, 0.15 or less entire depth
    ov

    foundations, structural elements exposed to


    the atmosphere at two or more sides; 0.15 0.6 one half the thickness or
    0.15 whichever is greater
    o

    concrete products
    it

    Massive sections 0.6 or greater 0.6


    et
    m

    1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples
    that are required for all tests, in that case, the necessary additional quantity of concrete in
    pieces of appropriate minimum size should be taken at each sampling location.

    2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as
    not to lose the core by its falling from the barrel and to make it easier to patch the core hole.

    13.2.2 Drilling Cores

    1 Before beginning coring operations the Contractor shall use a proprietary cover meter to
    identify the position of steel reinforcing bars at the testing location.
    QCS 2014 Section 05: Concrete Page 6
    Part 13: Inspection and Testing of Hardened Concrete

    2 The Engineer may instruct that the core is taken through the concrete without hitting any
    reinforcement or the Engineer may instruct that the core is taken in a position where it is
    expected reinforcement will be cut in order to provide a sample of the reinforcement to check
    its condition. The locations of all drilling points shall be chosen so that the core contains no
    steel parallel to its length.

    3 Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared
    for test the core shall have a length at least equal to the diameter and not more than 1.2
    times its diameter.

    4 Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the
    aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm
    cores should be taken to reduce the variability due to drilling and increase the reliability of the
    testing, unless reinforcement is congested and the use of 100 mm cores will reduce the
    possibility that the core will contain steel or it is necessary to restrict the sampling to a length

    l .
    of less than 150 mm.

    .l.
    rw
    5 Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores
    may be used with the permission of the Engineer.

    6
    ta
    During drilling operations, a log of observations that may affect the interpretation of core
    qa
    samples shall be prepared.

    7 If instructed by the Engineer, immediately after the core has been cut and removed and the
    as

    structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein


    poured over the cut surface. A photograph shall be taken of the cut core with the
    se

    phenolphthalein solution applied to provide a record of the test.


    er

    8 If during the drilling of the core, the core collapses due to weak honeycombed or defective
    concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent
    ov

    location as advised by the Engineer. If when testing at the second location, the core again
    breaks due to honeycombed or defective concrete the freshly cut core shall be retained for
    reference and a note made of the condition.
    it o

    13.2.3 Testing for Strength


    et

    1 The compressive strength of field concrete cores shall be assessed in accordance with BS
    m

    EN 13791.

    2 The details of the concrete core in accordance with BS EN 13791 shall be recorded and two
    photographs on either side of the core taken.

    3 Where there is reinforcement in the core, the size and the type of bar shall be noted along
    with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a
    detailed description of any corrosion of the reinforcement.

    4 Before carrying out the compressive strength testing of the cores, the Contractor shall inform
    the Engineer to allow him to witness the testing if required.

    5 Crushed core samples shall be retained by the laboratory and only disposed of after written
    approval by the Engineer.
    QCS 2014 Section 05: Concrete Page 7
    Part 13: Inspection and Testing of Hardened Concrete

    13.2.4 Assessment of Strength

    1 The estimated in-situ strength of the concrete shall be calculated from the core result using
    BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.

    13.3 REINFORCEMENT COVER MEASUREMENTS

    1 The measurement of cover to reinforcing steel and other metallic items in concrete shall be
    carried out in accordance with BS 1881 Part 204 using an electromagnetic device that
    estimates the position depth and size of the reinforcement.

    2 The locations for checking cover and the spacing between measurements shall be advised
    by the Engineer based on the objective of the investigation. The Contractor shall carry out
    calibrations of the electric magnetic device for a particular bar size to allow the bar diameter

    .
    to be measured.

    l
    .l.
    3 While testing, the orientation of steel bars shall be checked.

    rw
    4 The electromagnetic device shall incorporate scale or digital display range and shall be
    calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the

    ta
    indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever
    qa
    is the greater over the working range given by the manufacturer.

    5 The cover meter shall be used in accordance with the manufacturers instructions and checks
    as

    on the zero carried out as specified.


    se

    6 The search head shall be traversed systematically across the concrete, and, where
    reinforcement is located, rotated until the maximum disturbance with electromagnetic field is
    er

    indicated by the meter.


    ov

    7 The cover to the reinforcement shall be noted along with the axis of the reinforcement. The
    cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent
    marking pen.
    it o

    8 Care should be taken to avoid interference from other metallic sources or magnetic material.
    et

    9 The cover meter checks shall be carried out by an operator with five years experience.
    m

    10 The test report on cover shall include the following information:

    (a) date
    (b) time and place of test
    (c) description of the structure or component under investigation
    (d) location of test areas
    (e) make and type of cover meter used
    (f) date of last laboratory calibration of cover meter
    (g) details of site calibration of cover meter, indicated values of cover
    (h) estimated accuracy of quantitative measurements
    (i) configuration of steel reinforcement
    QCS 2014 Section 05: Concrete Page 8
    Part 13: Inspection and Testing of Hardened Concrete

    13.4 ULTRASONIC PULSE MEASUREMENTS

    13.4.1 General

    1 The ultrasonic velocity test equipment shall be capable of measuring the transit time of a
    pulse vibration through concrete. The length of the pulse part between the transducer
    equipment shall be measured, and the pulse velocity calculated.

    2 Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS
    EN 12504-4.

    3 Velocities shall be measured at a number of locations around a structure and a velocity


    contour of the structure established. A minimum of 40 velocities shall be measured for each
    structural element.

    l .
    13.4.2 Selection of Test Locations

    .l.
    rw
    1 Wherever possible direct transmission arrangements shall be used. The transducers shall be
    mounted on a specially formed moulded surface.

    2
    ta
    The minimum path length shall be 100 mm for concrete in which the nominal maximum size
    qa
    of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size
    of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than
    required to detect small regions of bad concrete.
    as

    3 Where concrete contains steel the pulse velocity shall be adjusted in accordance with the
    se

    requirement of BS EN 12504-4.
    er

    4 Locations that contain reinforcement directly along or close to the pulse paths shall be
    avoided.
    ov

    5 Where repositioning is not possible the semi-direct transmission measurement, where


    transducers are placed on adjacent faces of the concrete, may be used.
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    13.4.3 Execution of Tests


    et

    1 Positions chosen for the test locations shall be clearly and accurately marked on the surface
    m

    of the concrete.

    2 The surface of the concrete shall be shall be cleaned and free from grit and dust. Path
    lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease)
    applied to each of the test points.

    3 Pulse transit times shall be measured by a skilled operator, with a minimum of five years
    experience in the use of the equipment.

    4 Pulse velocity measurement equipment shall be in accordance with the requirements of BS


    EN 12504-4.

    5 Test results shall be examined and any unusual readings repeated carefully for verification or
    amendment.
    QCS 2014 Section 05: Concrete Page 9
    Part 13: Inspection and Testing of Hardened Concrete

    13.4.4 Estimated In-Situ Cube Strength

    1 A correlation shall be established between the cube crushing strength of the particular mix
    used in the structure and the pulse velocity.

    2 Where it is not possible to obtain cubes with the same mix design as the original structure a
    combination of coring and ultrasonic pulse velocity testing may be carried out at the direction
    of the Engineer, where the cores are used to provide the correlation information required for
    the interpretation of the ultrasonic pulse velocity tests.

    13.5 RADIOGRAPHY OF CONCRETE

    1 Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects:
    The testing shall be carried out in accordance with the requirements of BS 1881-205 or

    .
    equivalent.

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    .l.
    13.6 SURFACE HARDNESS

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    13.6.1 General

    1
    ta
    Testing of concrete surfaces for hardness using rebound hammers shall be carried out in
    qa
    accordance with BS EN 12504-2.

    2 The rebound hammer shall only be used for estimation of concrete strength where a specific
    as

    correlation is carried out of the concrete from the structure being tested; this shall be from
    works test cubes or cores taken from the structure.
    se

    3 The correlation between concrete strength and the rebound number shall be carried out in
    er

    accordance with BS EN 12504-2. The precision of the correlation curve between the mean
    rebound number and strength shall be stated and this shall be used when reporting any
    ov

    strength interpretations from surface hardness readings. The use of general manufacturers
    correlation or calibration curve for strength shall not be used.
    o

    4 It should be noted that the rebound hammer number only provides information on a surface
    it

    layer of approximately 30 mm in depth of the concrete and that this should be quoted in the
    et

    test report.
    m

    5 The rebound hammer maybe used to establish the uniformity of the finish products or similar
    elements in a structure at a constant age, temperature, maturity and moisture condition.

    13.6.2 Method of Test

    1 A minimum of 12 readings shall be taken to establish a single surface hardness at a


    particular location.

    2 The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not
    exceeding 300 mm by 300 mm.

    3 The mean of each set of readings shall be calculated including abnormally high and
    abnormally low results unless there is good reason to doubt the validity of a particular
    reading.

    4 The coefficient of variation and the standard deviation of the readings shall be reported.
    QCS 2014 Section 05: Concrete Page 10
    Part 13: Inspection and Testing of Hardened Concrete

    13.6.3 Equipment

    1 The rebound hammer shall be a proprietary type that has been used successfully and
    serviced for a minimum of five years.

    2 The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact
    with the surface.

    3 The manufacturers literature shall identify the impact energy and contact area of the plunger
    for the hammer.

    13.6.4 Reporting

    1 The test report shall affirm that the hardness was determined in accordance with BS EN
    12504-2 and shall provide the following information:

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    (a) date time and place of test

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    (b) description of structure and location of test
    (c) details of concrete
    (d) type of cement
    ta
    qa
    (e) cement content
    (f) type of aggregate
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    (g) type of curing


    se

    (h) age of concrete


    (i) type of compaction of concrete
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    (j) forming of surface


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    (k) moisture condition of the surface


    (l) carbonation state of surface
    o

    (m) any suspected movement of the concrete under test


    it
    et

    (n) direction of test


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    (o) any other factors that are considered significant in influencing the hardness readings.

    2 The details of the rebound hammer correlation with strength including the mean, range,
    standard deviation and coefficient and variation of each reading shall also be included.

    13.7 CHEMICAL CONTENT

    13.7.1 Sampling

    1 The Engineer shall instruct the depth increments over which the dust samples are to be
    taken, the types of chemical testing to be carried out and the quantity of sample required.

    2 The depth of sample shall not be less than the concrete cover to the reinforcement and at
    least 50 mm from the surface of concrete. In presence of reinforcement, the chemical
    content shall be tested at least at two levels before and after the depth of reinforcement from
    the surface of concrete.
    QCS 2014 Section 05: Concrete Page 11
    Part 13: Inspection and Testing of Hardened Concrete

    3 To provide uniform samples of cement matrix and aggregate, three separate holes shall be
    drilled at one location. The diameter of the holes shall be between 12 and 20 mm.

    4 Care shall be taken to discard the material from any render or finish unless this is specifically
    required under the investigation.

    5 Care shall be taken to ensure that dust increments are accurately measured by marking the
    drill bit.

    6 The dust samples increments shall be carefully transferred to plastic bags and sealed to
    avoid contamination. Each sealed bag shall be uniquely identified by the sample identification
    and depth increment.

    13.7.2 Laboratory Testing

    l .
    1 Residual split samples of dust from the field investigation shall be retained until the Engineer

    .l.
    has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried

    rw
    out on certain samples.

    2 Chloride testing of concrete dust samples shall be by an acid soluble method in accordance

    ta
    with BS 1881 Part 124. The results shall be reported to two decimal places.
    qa
    3 Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124,
    using an acid soluble method.
    as

    END OF PART
    se
    er
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    it o
    et
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    QCS 2014 Section 05: Concrete Page 1
    Part 14: Protective Treatments for Concrete

    14 PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2


    14.1 GENERAL ............................................................................................................... 2
    14.1.1 Scope 2
    14.1.2 References 2
    14.1.3 Submittals 2
    14.1.4 Quality Assurance 3
    14.1.5 Preinstallation and Co-ordination 4
    14.1.6 Delivery, Storage and Handling 4
    14.1.7 Protection 4
    14.1.8 General Requirements for all Treatments 5
    14.1.9 Final Inspection 5
    14.2 EPOXY COATING ................................................................................................... 5

    .
    14.2.1 General 5

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    .l.
    14.2.2 Surface Preparation 5
    14.2.3 Materials 6

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    14.2.4 Application 6
    14.3 WATERPROOF MEMBRANE ................................................................................. 6
    14.3.1 General ta 6
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    14.3.2 Materials 7
    14.3.3 Waterproof Membrane 7
    14.3.4 Application 7
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    14.4 PENETRATIVE PRIMER ......................................................................................... 8


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    14.4.1 General 8
    14.4.2 Material 8
    er

    14.4.3 Surface Preparation 8


    14.4.4 Application 8
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    14.5 PROTECTIVE COATING ........................................................................................ 9


    14.5.1 General 9
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    14.5.2 Surface Preparation 9


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    14.5.3 Material 10
    14.5.4 Application 10
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    14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11


    14.6.1 General 11
    14.6.2 Shop Drawings and Submittals 11
    14.6.3 Liner Material Requirements 11
    14.6.4 Plastic Sheet Liner Strip Properties 12
    14.6.5 Basic Sheet Dimensions 12
    14.6.6 Liner Details 12
    14.6.7 Installation 13
    14.6.8 Testing Requirements 13
    14.6.9 Special Requirements 14
    14.6.10 Joints in Lining for In-Situ Concrete Structures 15
    14.6.11 Testing and repairing damaged surfaces 15
    QCS 2014 Section 05: Concrete Page 2
    Part 14: Protective Treatments for Concrete

    14 PROTECTIVE TREATMENTS FOR CONCRETE

    14.1 GENERAL

    14.1.1 Scope

    1 This Part covers the materials and application requirements for coatings for concrete
    surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective
    coatings, and coatings and treatments for specialist applications where there is a harsh
    environment.

    2 Related Section and Parts are as follows:


    This Section

    .
    Part 1, ............. General

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    .l.
    14.1.2 References

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    1 The following standards are referred to in this Part:

    ta
    ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers
    Tension
    qa
    ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents
    ASTM D570 ................Test Method for Water Absorption of Plastics
    as

    ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)


    ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers
    se

    by Impact
    ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting
    er

    ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for
    ov

    Electrical and Electronic Applications


    ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting
    o

    ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion
    it

    Testers
    et

    ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials


    ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth
    m

    Under Concrete Slabs, on Walls, or as Ground Cover


    BS 1881......................Testing Concrete
    BS EN 12350..............Testing fresh concrete

    CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments.


    ISO 9000 ....................Quality management and quality assurance standards
    ISO 9001 ....................Quality systems - Model for quality assurance in design, development,
    production, installation and servicing

    14.1.3 Submittals

    1 The Contractor shall submit manufacturers' specifications, installation instructions and other
    data to show compliance with the requirements of this part of the specification and the
    Contract Documents.
    QCS 2014 Section 05: Concrete Page 3
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall submit samples of all materials to be used in the works before delivery
    of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples
    of liquid components shall be a minimum of one litre.

    3 The Contractor shall submit comprehensive test results for the protective coating system as
    per the tests in the specification which shall clearly indicate whether the values are mean
    values measured in current production or minimum values which the property does not fall
    below.

    4 The Contractor shall clearly state the chemical composition of the material and the process
    by which protection is given to the concrete.

    5 In addition to the test methods identified in this clause of this specification, the Engineer may
    require the Contractor to carry out further tests to different standards.

    l .
    6 If the Contractor wishes to propose a material which has been tested to alternative

    .l.
    standards, the Contractor shall submit correlation tests showing the comparable values of the

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    two test methods. These test results shall be comprehensive giving full details of the sample
    conditioning, preparation, method of test, criteria for assessment etc.

    7
    ta
    The Contractor shall submit comprehensive information of previous applications of the
    material in similar conditions and environments. This information shall include: project name,
    qa
    type/grade of material used, quantity of material used, name of client, name of consultant,
    name of Contractor. If requested by the Engineer, the Contractor shall supply the contact
    as

    details of the client, consultant or Contractor where the material was previously installed.
    se

    8 The Contractor shall submit a guaranty for the protective coating system and the
    workmanship. The guaranty shall be worded to reflect the required performance of the
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    material and shall be approved by the Engineer. The guaranty shall be worded to include the
    phrase the Contractor shall, at the convenience of the Employer, effect all repairs and
    ov

    replacements necessary to remedy defects all to the complete satisfaction of the Engineer.
    Unless stated otherwise in the contract specific documentation, the performance guaranty
    shall be for a period of ten years except for the penetrative primer which shall be for a period
    o

    of five years.
    it
    et

    9 The use of alternatives may be considered by the Engineer. If the Contractor wishes to
    propose such systems, a technical submission shall be made which shall include a
    m

    comprehensive justification giving an explanation of why the proposed system is equivalent


    or superior to the one designated.

    14.1.4 Quality Assurance

    1 The protective coating system shall be supplied by a manufacturer who is certified to the
    ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of
    the ISO 9000 series certificate that clearly states the scope of the certification.

    2 The protective coating system shall be supplied by a manufacturer who provides technical
    assistance on the suitability for the application and installation for the material. For the initial
    use of the material on Site, the Contractor shall arrange for the technical representative of
    the manufacturer to be present to demonstrate the correct use of the material.
    QCS 2014 Section 05: Concrete Page 4
    Part 14: Protective Treatments for Concrete

    3 The protective coating system shall be applied by a contractor or subcontractor who is


    certified to the ISO 9000 series of quality standards. The Contractor shall submit to the
    Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification.
    the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the
    applicator works to a quality system that is approved by the Engineer.

    4 The works shall be executed by an approved specialist subcontractor having a minimum of 5


    years successful experience in the installation of the specified material. Only tradesmen
    experienced with the installation of the materials specified shall be used.

    14.1.5 Preinstallation and Co-ordination

    1 After approval of all materials and before installation, a prework conference with the Engineer
    shall be held at the Site. The meeting shall be attended by representatives of the Engineer,
    Contractor, subcontractor, and manufacturer.

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    2 The parties shall:

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    (a) review drawings, specifications and approved materials
    (b) correct conflicts, if any, between approvals and specification requirements
    (c) ta
    examine Site conditions, including inspection of substrate, material labels and
    qa
    methods of storing materials
    (d) review installation procedures and scheduling
    as

    (e) review protection methods for finished work from other trades.
    se

    3 Before applying the coating system to the permanent works the Contractor shall carry out a
    small trial of the coating system for the review and approval of the Engineer.
    er

    14.1.6 Delivery, Storage and Handling


    ov

    1 Materials shall be delivered in their original, tightly sealed containers or unopened packages,
    o

    all clearly labelled with the manufacturer's name, brand name, and number and batch
    number of the material where appropriate. Materials and equipment shall be stored as
    it

    directed in a neat and safe manner.


    et
    m

    2 Storage areas shall comply with the manufacturers requirements with regard to shade,
    ventilation and temperature limits and shall be located away from all sources of excess heat,
    sparks or open flame. Containers of liquid material shall not be left open at any time in the
    storage area.

    3 Materials not conforming to these requirements will be rejected by the Engineer and shall be
    removed from the Site and replaced with approved materials.

    4 The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and
    at such times as to permit proper co-ordination of the various parts.

    14.1.7 Protection

    1 The Contractor shall protect the protection system installation from damage during the
    construction period so that it will be without any indication of abuse, defects or damage at the
    time of completion.
    QCS 2014 Section 05: Concrete Page 5
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall protect the building/structure from damage resulting from spillage,
    dripping and dropping of materials.

    3 The Contractor shall prevent any materials from running into and clogging drains.

    4 Materials and plant shall not be stored on any newly constructed floor without the permission
    of the Engineer.

    5 Impervious membranes shall be laid as protection to all concrete surfaces in contact with the
    soil and shall consist of tanking or similar accepted material, based on soil investigation
    report.

    6 All foundations shall be provided with protection such as epoxy coatings or similar other
    accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

    l .
    14.1.8 General Requirements for all Treatments

    .l.
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    1 Protective treatments shall be applied where designated in the contract specific
    documentation.

    2
    ta
    All protective coating systems to be used shall be applied strictly in accordance with the
    manufacturers recommendations.
    qa
    3 The Contractor shall take all necessary precautions against fire and other hazards during
    as

    delivery, storage and installation of flammable materials specified herein and comply any
    regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect
    of the storage and use of hazardous materials required under this section.
    se

    4 The Engineer shall specify the required final colour of the coating and the Contractor shall
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    submit samples showing the colour before ordering the materials.


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    14.1.9 Final Inspection


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    1 Upon completion of the installation, an inspection shall be made by a representative of the


    it

    material manufacturer in order to ascertain that the system has been properly installed.
    et

    14.2 EPOXY COATING


    m

    14.2.1 General

    1 The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in
    two coats to a dry film thickness of 200 m minimum.

    14.2.2 Surface Preparation

    1 The surface of the concrete shall be free from oil, grease, loose particles, decayed matter,
    moss or algae growth and general curing compounds. All surface contamination and surface
    laitance shall be removed by high pressure water jetting or sweep blasting.

    2 Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic
    epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with
    the product manufacturers recommendations.
    QCS 2014 Section 05: Concrete Page 6
    Part 14: Protective Treatments for Concrete

    3 Where surface cracking is apparent these cracks shall be chased, by an approved


    mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using
    a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased
    section and providing a flush finish with the concrete surface. A minimum period of 24 h shall
    be allowed before applying any subsequent protective coating systems.

    14.2.3 Materials

    1 External above ground coating materials shall provide protection against chlorides and
    carbonation, and be UV and abrasion resistant.

    2 The above ground coating shall be applied over the below ground coating and shall continue
    for a minimum of 150 mm above the ground level.

    3 The epoxy coating shall be UV stable.

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    4 The finished coating shall be pinhole free and have a total minimum dry film thickness of

    rw
    200 m.

    5 The materials used in the coating system shall comply with the following requirements:

    ta
    qa
    Solids content > 85 %
    Service temperature -20 C to 70 C
    Tensile strength (DIN 53504) 4 MPa
    as

    Resistance against crack (DIN 53515) 6 MPa


    Adhesion to concrete (ASTM D-4541) greater than 3.5 MPa
    Compressive strength (ASTM D-695) 90 MPa (neat resin)
    se

    Tensile elongation (ASTM D-638) 6-8 % (neat resin)


    Water absorption (MIL D-24613) Nil
    er

    Abrasion resistance (ASTM C-501) 50 mg


    Compressive strength (ASTM C-579) 97 MPa @ 7 days
    ov

    -6
    Thermal coefficient of expansion (ASTM C-531) 46.8 x 10 mm/mm/degree C
    o

    14.2.4 Application
    it
    et

    1 Where required by the Engineer, trial areas not exposed in the finished work shall first be
    treated using the selected materials.
    m

    2 The exposed concrete surfaces as defined in the documents or as agreed with the Engineer
    shall be treated with the material.

    3 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the
    Engineer.

    4 In all operations of storage, mixing and application, the Contractor is to comply with the
    health and safety recommendations of the manufacturer and governing authorities.

    14.3 WATERPROOF MEMBRANE

    14.3.1 General

    1 This Subpart covers the use of waterproof membrane for general protection to buried
    concrete.
    QCS 2014 Section 05: Concrete Page 7
    Part 14: Protective Treatments for Concrete

    2 Where indicated on the Drawings or directed by the Engineer, concrete in contact with the
    ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.

    3 The laying, lapping and sealing of the membrane shall be in accordance with the
    manufacturers instructions.

    14.3.2 Materials

    1 The material shall be an externally applied waterproof membrane shall be an impervious,


    cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated
    polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with
    silicone coated release paper.

    2 Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

    l .
    3 Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured

    .l.
    from selected aggregates, bound in modified bitumen encased between two layers of

    rw
    strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick
    and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm
    wide.

    14.3.3 Waterproof Membrane ta


    qa
    1 The material shall be suitable for use in the Gulf region the compound shall be specially
    as

    formulated for hot climates and shall have proven experience in the Middle East.
    se

    2 The waterproofing material shall conform to the standards detailed in Table 14.1
    er

    Table 14.1
    Waterproof Membrane Property Requirements
    ov

    Property Standard Value


    o

    Longituduial 210 %
    Elongation Film ASTM D638
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    Transverse 160 %
    et

    Longitudinal 340 MPa


    Tear resistance ASTM D1004
    Transverse 310 MPa
    m

    Adhesion to primed concrete ASTM D1000 1.8 MPa

    Elongation compound ASTM D1000 1.8 MPa

    Puncture resistance ASTM E154 220 N over 65 mm


    After 24 h. 0.14 %
    Water resistance ASTM D570
    After 35 d 0.95 %
    Environmental resistance ASTM D543
    2
    Moisture vapour transmission rate ASTM E96 0.3g/M 24 h
    Minimum thickness 1.0 mm.

    14.3.4 Application

    1 Waterproofing membranes placed on vertical concrete faces shall be protected by preformed


    asphalt board.
    QCS 2014 Section 05: Concrete Page 8
    Part 14: Protective Treatments for Concrete

    2 Boards shall be bonded onto position with high quality solvent borne contact adhesive based
    on polychloroprene rubber.

    3 The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains,
    equipment bases and other adjacent work and mask adjacent work to prevent soil marks.

    4 Areas where waterproofing is applied shall be protected from all traffic and where necessary
    backfilling. All damage to finished portions of the waterproofing membrane shall be either
    repaired or replaced, or both, in a manner acceptable to the Engineer.

    14.4 PENETRATIVE PRIMER

    14.4.1 General

    1 The system shall be a penetrating hydrophobic treatment that protects concrete from both

    l .
    water and chloride intrusion, while permitting water vapour transmission.

    .l.
    rw
    2 The treatment shall significantly reduce the absorption of water and water borne salts but
    allow the transmission of water vapour from the substrate.

    3
    ta
    The treatment shall not produce any discoloration of the substrate and shall have excellent
    qa
    resistance to weathering.

    14.4.2 Material
    as

    1 The material shall be a low viscosity silane-siloxane system which penetrates deeply into a
    se

    porous substrate and reacts to produce a bonded hydrophobic lining to the pores.
    er

    2 The material shall be resistant to petrol, oil, and atmospheric contaminants such as car
    exhaust fumes and industrial exhausts.
    ov

    14.4.3 Surface Preparation


    o

    1 The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae
    it

    growth and curing compounds.


    et

    2 If the concrete surface is newly cast and has a very smooth finish, the surface shall be
    m

    roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer
    shall decide if this means of preparation is required.

    3 Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in
    accordance with the manufacturers recommendations.

    4 Concrete finishing required shall be completed before the application of the treatment.

    5 Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturers
    recommendations.

    14.4.4 Application

    1 Unless directed otherwise by the Engineer the treatment shall be applied a minimum period
    of 24 h after the wet curing period, and shall be surface dry.
    QCS 2014 Section 05: Concrete Page 9
    Part 14: Protective Treatments for Concrete

    2 The Contractor shall carry out tests to verify the depth of penetration of the material. These
    tests shall be carried out on specimens of the actual mix design and shall use coloured dyes
    to trace the penetration of the material.

    3 Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for
    reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats'
    of the treatment shall be applied before the main treatment.

    4 The application of the material on surfaces shall be by a low pressure spray direct from the
    can. Under no circumstances should thinning of the material be carried out.

    5 The rate of application shall ensure that the surface is completely saturated. The
    impregnated coating shall be applied to two or more flood coats each flood coat shall be a
    2
    minimum of 0.4 l/m .

    l .
    6 The material shall be applied strictly in accordance with the manufacturers instructions and

    .l.
    as follows:

    rw
    (a) the material shall be applied by a fine nozzle spray
    (b) application will not be permitted when the ambient air temperature is above 35 C or
    in windy conditions
    ta
    qa
    (c) the surface shall be cleaned by a stiff brush or compressed air to remove all loose
    deposits
    as

    (d) concrete to be treated shall be surface dry for a minimum period of 24 h before
    impregnation
    se

    (e) membranes, joint sealers and cast in concrete ancillaries shall be masked off before
    treatment
    er

    (f) application shall be made by saturation flooding


    ov

    (g) the interval between application shall be at least 6 h


    (h) treated areas shall be protected from sea water and rain for 6 h after treatment.
    it o
    et

    14.5 PROTECTIVE COATING


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    14.5.1 General

    1 The coating system shall be used for the protection of new or existing reinforced concrete
    structures against carbonation or chloride induced corrosion.

    2 The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat
    system to minimise ingress of acidic gases, chlorides and water.

    14.5.2 Surface Preparation

    1 Before application, all surfaces must be dry and free from oil, grease, loose particles,
    decayed matter, moss or algae growth and general curing compounds.

    2 All such contamination and laitence must be removed by the use of grit blasting, high
    pressure water jetting or equivalent mechanical means.
    QCS 2014 Section 05: Concrete Page 10
    Part 14: Protective Treatments for Concrete

    3 Before proceeding to apply the protective coatings, all surfaces which are not to be coated
    but which may be affected by the application of the coating shall be fully masked and, in
    particular, flora and fauna shall be protected.

    4 Blow holes and areas of pitting shall be made good with a one part modified cementitious
    material and allowed to cure in accordance with the manufacturer's recommendations. In
    particular, the application shall be in accordance with the manufacturer's recommendations,
    with respect to the maximum application thickness.

    14.5.3 Material

    1 The materials are required to provide in-depth protection against carbonation and chloride
    penetration whilst permitting water vapour transmission from the concrete.

    2 The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a

    l .
    porous substrate and reacts to produce a bonded hydrophobic lining to the pores.

    .l.
    rw
    3 The material employed for the coating shall comply with the following requirements:
    Wet film thickness 400 m
    Dry film thickness 200 m
    Carbon Dioxide diffusion resistance
    ta R Value at 325 microns > 161 metres.
    qa
    (Taywood Engineering Laboratories)
    Water vapour transmission
    2
    (Taywood Engineering Laboratories) Shall be more than 13 g/m .d
    Reduction in chloride ion penetration 94 % minimum at 28 d
    as

    (BS 1881 : Part 124)


    2
    Tear Resistance (ASTM D624) 7.3 kN/mm
    se

    Crack bridging (BRE Method) 5.1 mm


    Chloride Ion Diffusion
    er

    -10 2
    (Taywood Engineering Labororatories) 3.63 x 10 cm /sec.
    4 Where test methods are not specified, the procedure for establishing compliance with the
    ov

    above criteria shall be agreed with the Engineer.


    o

    5 The Contractor is required to adhere strictly to the manufacturer's recommendations


    it

    regarding the use, storage, application and safety rules in respect of the approved materials.
    et

    14.5.4 Application
    m

    1 Where required by the Engineer, trial areas not exposed in the finished work shall first be
    treated using the selected materials. These trial areas shall be noted on the Drawings and
    shall be carried out using the type of materials, mixing procedures and applications that will
    be used on the contract and shall be approved by the Engineer before the Contractor
    commences with the general work.

    2 The exposed concrete surfaces as defined in the documents or as agreed with the Engineer
    shall be conditioned by the application of a penetrating hydrophobic treatment. The primer
    shall be allowed to dry in accordance with the manufacturer's requirements.

    3 The Contractor shall then apply two coats of pigmented topcoat in accordance with the
    manufacturer's instructions. The finished coating shall be pinhole free and have a total
    minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the
    Engineer.
    QCS 2014 Section 05: Concrete Page 11
    Part 14: Protective Treatments for Concrete

    4 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the
    Engineer.

    5 In all operations of storage, mixing and application the Contractor shall comply with the health
    and safety recommendations of the manufacturer and governing authorities.

    14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

    14.6.1 General

    1 This Subpart covers the supply and installation of sheet liners in reinforced concrete
    structures.

    2 The liner must be continuous and free of pinholes both across the joints and in the liner itself.

    l .
    3 All work for and in connection with the installation of the lining in concrete pipe and structure,

    .l.
    and the field sealing and welding of joints, will be done in strict conformity with all applicable

    rw
    specifications, instructions, and recommendations of the lining manufacturer.

    14.6.2 Shop Drawings and Submittals

    ta
    qa
    1 The Contractor shall submit to the Engineer for approval the following:

    (a) liner schedule


    as

    (b) material certifications


    (c) test results
    se

    (d) material samples


    er

    (e) the manufacturer of the lining will submit an affidavit attesting to the successful use
    ov

    of its material as a lining for sewer pipes and structures for a minimum period of
    five years in service conditions recognised as corrosive or otherwise detrimental to
    concrete.
    it o

    14.6.3 Liner Material Requirements


    et

    1 The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and
    m

    other components necessary to make a material of permanent flexibility suitable for a liner in
    concrete pipes and structures in sewerage service. The weld strips and the joint strips shall
    be made from like material. For PVC and PE sheet liners, the actual resin used in
    manufacture must constitute not less than 99 % of the resin used in the formulation.

    2 Copolymer resins will not be permitted.

    3 All plastic sheets including locking extensions, all joints and welding strips shall be free of
    cracks, asperities and other defects that may affect the protective properties of the material.

    4 The properties of PVC and PE sheet are shown in Table 14.2


    QCS 2014 Section 05: Concrete Page 12
    Part 14: Protective Treatments for Concrete

    Table 14.2
    Properties of PVC and PE Sheet Liners

    Property Test Method Requirement


    PVC
    Elongation at break ASTM D638/882 300 %
    Tensile Strength ASTM D638/412 15 MPa
    Low Temp. Brittleness ASTM D746 0C
    PE
    Elongation at break ASTM D638/882 Exceeds 600 %
    Tensile Strength ASTM D638/412 10-20 MPa
    Low Temp. Brittleness ASTM D746 -75 C

    14.6.4 Plastic Sheet Liner Strip Properties

    l .
    1 Except at shop welds, all plastic sheet liners and strips shall have the properties shown in

    .l.
    Table 14.3 when tested at 25 C.

    rw
    Table 14.3

    Property ta
    Properties of Plastic Sheet Liner Strips

    Requirement
    qa
    Tensile strength 15 MPa
    Elongation at break 200 %
    as

    1 s 50 - 60 5 (with respect to 10 s
    Shore Durometer
    35 - 50 5)
    se

    Weight change 1.5 %


    er
    ov

    14.6.5 Basic Sheet Dimensions

    1 The minimum thickness of the material shall be as shown in Table 14.4


    it o

    Table 14.4
    et

    Plastic Sheet Liner Minimum Dimensions


    m

    Material Thickness Structures


    Sheet with locking extensions 4.0 mm
    Sheet, plain 2.3 mm
    Joint strip 1.9 mm
    Weld strip 2.4 mm

    14.6.6 Liner Details

    1 Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be
    integrally extruded with the sheet.

    2 Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

    3 Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using
    an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall
    be repaired and retested.
    QCS 2014 Section 05: Concrete Page 13
    Part 14: Protective Treatments for Concrete

    14.6.7 Installation

    1 Installation of the lining, including preheating of sheets in cold weather and the welding of all
    joints, shall be performed in accordance with the recommendations of the manufacturer.

    2 The lining to be held snugly in place against inner forms by means of steel banding straps or
    other means recommended by the manufacturer.

    3 Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a
    careful manner to protect the lining and produce a dense, homogenous concrete, securely
    anchoring the locking extensions into the concrete.

    4 In removing forms care shall be taken to protect the lining from damage. In particular:

    (a) sharp instruments not to be used to pry forms from lined surfaces.

    l .
    (b) when forms are removed, any nails that remain in the lining to be pulled, without

    .l.
    tearing the lining, and the resulting holes clearly marked.

    rw
    (c) form tie holes to be marked before ties are broken off and all areas of serious
    abrasion or damage shall be marked.

    5
    ta
    All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be
    qa
    patched as follows:

    (a) patches made entirely with welding strip to be fused to the liner over the entire patch
    as

    area
    (b) larger patches may consist of smooth liner sheet applied over the damaged area with
    se

    adhesive
    er

    (c) all edges must be covered with welding strip fused to the patch and the sound lining
    adjoining the damaged area.
    ov

    6 Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.
    o

    7 The Contractor shall take all necessary measures to prevent damage to the installed lining
    it

    from equipment and materials used in or taken through the work.


    et

    14.6.8 Testing Requirements


    m

    1 Samples taken from sheets, joints or weld strips shall be tested to determine material
    properties. Determination of tensile strength and elongation shall be in accordance with
    ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with
    ASTM D 2240 using a Type D Durometer, except that a single thickness of material and
    indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of
    specimens shall be the thickness of the sheet or strip.

    2 The measurement of initial physical properties for tensile strength, weight, elongation and
    indentation hardness shall be determined before chemical resistance tests.

    3 Chemical resistance tests shall be carried out to determine the physical properties of the
    specimens after exposure to chemical solutions. Test specimens shall be conditioned to
    constant weight at 43 C before and after submersion in the solutions detailed in Table 14.5
    for a period of 112 d at 25 3 C.
    QCS 2014 Section 05: Concrete Page 14
    Part 14: Protective Treatments for Concrete

    4 Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals,


    specimens shall be removed from each chemical solution and tested. If any specimen fails to
    meet the 112 day exposure, the material will be subject to rejection.

    5 Pull test for locking extensions: Liner locking extensions embedded in concrete shall
    withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a
    period of 1 min, without rupture of the locking extensions or withdrawal from embedment.
    This test shall be made at a temperature between 21 C to 27 C inclusive.

    6 Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together,
    shall be a least equal to the minimum requirements of the liner for thickness, corrosion
    resistance and impermeability. Welds shall show no cracks or separations and shall be
    tested for tensile strength. Tensile strength measured across the welded joint in accordance
    with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25 3 C

    .
    and the measured minimum width and thickness of the reduced section shall be used.

    l
    .l.
    7 Spark test: All liner shall be shop tested for holes with a spark tester set to provide from

    rw
    15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before
    shipment from the manufacturers plant.

    8
    ta
    The Contractor shall provide the Engineer with certified copies of test reports before the
    qa
    shipment of the product to the Site.
    Table 14.5
    Chemical Resistance Tests
    as

    Chemical Solutions Concentration


    se

    Sulphuric Acid 20 %
    Sodium Hydroxide 5%
    er

    Ammonium Hydroxide 5%
    ov

    Nitric Acid 1%
    Ferric Chloride 1%
    o

    Soap 0.1 %
    it

    Detergent (Linear alkyl benzyl sulphonate or LAS) 0.1 %


    et

    Bacteriological BOD not less than 700 mg/l


    m

    Phosphoric Acid 50 %

    14.6.9 Special Requirements

    1 Liner sheets to be closely fitted and properly secured to the inner forms.

    (a) sheets that are to be cut to fit curved and warped surfaces shall use a minimum
    number of separate pieces
    (b) a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt
    joints to prevent wet concrete from flowing around the edges.

    2 Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the
    surfaces of contact between the concrete structure and items not of concrete and

    (a) the same procedure will be followed at joints where the type of protective lining is
    changed or the new work is built to join existing unlined concrete
    QCS 2014 Section 05: Concrete Page 15
    Part 14: Protective Treatments for Concrete

    (b) at each return, the returned liner will be sealed to the item in contact with the plastic
    lined concrete with an adhesive system
    (c) if the liner cannot be sealed with this adhesive because of the joint at the return being
    too wide or rough or because of safety regulations, the joint space shall be densely
    caulked with lead wool or other approved caulking material to a depth of 50 mm and
    finish with a minimum of 25 mm of an approved corrosion resistant material.

    14.6.10 Joints in Lining for In-Situ Concrete Structures

    1 Field joints and Lining at joints shall be free of all mortar and other foreign material and shall
    be clean and dry before joints are made.

    2 All welding is to be in strict conformance with the specifications of the lining manufacturer.

    .
    14.6.11 Testing and repairing damaged surfaces

    l
    .l.
    1 All surfaces covered with lining, including welds, will be tested with an approved electrical

    rw
    holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:

    (a) all welds shall be physically tested by a non-destructive probing method


    (b) ta
    all patches over holes, or repairs to the liner wherever damage has occurred.
    qa
    2 Each transverse welding strip which extends to a lower edge of the liner will be tested by an
    approved testing agency at the cost of the Contractor.
    as

    (a) the welding strips will extend 50 mm below the liner to provide a tab.
    se

    (b) a 5 kg pull will be applied to each tab. The force will be applied normal to the face of
    the structure by means of a spring balance
    er

    (c) liner adjoining the welding strip will be held against the concrete during application of
    ov

    the force
    (d) the 5 kg pull will be maintained if a weld failure develops until no further separation
    o

    occurs.
    it

    (e) defective welds will be retested after repairs have been made
    et

    (f) tabs shall be trimmed away neatly by the installer of the liner after the welding strip has
    m

    passed inspection.
    (g) inspection will be made within two days after joints has been completed in order to
    prevent tearing the projecting weld strip and consequent damage to the liner from
    equipment and materials used in or taken through the work.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 15: Hot Weather Concreting

    15 HOT WEATHER CONCRETING ............................................................................. 2


    15.1 GENERAL ............................................................................................................... 2
    15.1.1 Scope 2
    15.1.2 References 2
    15.1.3 Definition of Hot Weather 2
    15.1.4 System Description 3
    15.1.5 Submittals 3
    15.2 PLACING TEMPERATURE ..................................................................................... 3
    15.3 PLANNING CONCRETING ..................................................................................... 4
    15.4 MIX DESIGN ........................................................................................................... 4
    15.5 TEMPERATURE CONTROL ................................................................................... 4
    15.5.1 General 4

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    15.5.2 Aggregates 4

    .l.
    15.5.3 Water 5

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    15.5.4 Cement 5
    15.5.5 Addition of Ice 5
    15.5.6 Liquid Nitrogen
    ta 6
    qa
    15.6 BATCHING AND MIXING ........................................................................................ 6
    15.7 TRANSPORTATION ............................................................................................... 6
    15.8 PLACING AND FINISHING ..................................................................................... 6
    as

    15.9 CURING AND PROTECTION.................................................................................. 7


    se

    15.10 INSPECTION AND TESTING .................................................................................. 7


    er
    ov
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 15: Hot Weather Concreting

    15 HOT WEATHER CONCRETING

    15.1 GENERAL

    15.1.1 Scope

    1 This Part covers the precautions to be taken for hot weather concreting for all structural
    concrete except blinding concrete, where a minimum compressive strength is specified.

    2 Related Sections and Parts are as follows:

    This Section
    Part 6, .............. Property Requirements
    Part 7, .............. Concrete Plants

    l .
    Part 8 .............. Transportation and Placing of Concrete

    .l.
    Part 10 ............. Curing

    rw
    15.1.2 References
    ACI 305R-91...............American Concrete Institute , Hot Weather Concreting

    ta
    ASTM C1064 ..............Measuring the Temperature of Concrete
    qa
    BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for
    as

    buildings
    BS EN 480..................Admixtures for concrete, mortar and grout. Test methods
    se

    BS EN 934..................Admixtures for concrete, mortar and grout


    er

    15.1.3 Definition of Hot Weather


    ov

    1 The requirements of the following clauses of the specification are applicable during the hot
    weather period in Qatar.
    o

    2 The hot weather period shall be defined as starting when the maximum ambient air shade
    it

    temperature on the Site exceeds 35 C for three consecutive days. The end of the hot
    et

    weather period shall be defined as the period when the maximum air shade temperature is
    below 35 C on three consecutive days.
    m

    3 The Contractor shall establish a thermometer on Site that records the ambient air shade
    temperature. The thermometer shall be established at a position to provide representative air
    temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange
    for the calibration of the Site thermometer.

    4 Hot Weather shall mean any combination of the following conditions that tends to impair the
    quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and
    rate of cement hydration, or otherwise causing detrimental results such as:

    (a) High ambient temperature (when the shade temperature is above 40 deg C on a rising
    thermometer, 43 deg C on a falling thermometer),
    (b) High concrete temperature,
    (c) Low relative humidity,
    (d) High wind speed
    QCS 2014 Section 05: Concrete Page 3
    Part 15: Hot Weather Concreting
    2
    (e) the rate of evaporation exceeds 0.75 kg/m /h

    15.1.4 System Description

    1 The Contractor shall undertake hot weather concreting procedures that are effective in
    controlling the following potential problems associated with concreting in hot weather:

    (a) increased water demand of the mix


    (b) increased rate of slump loss
    (c) increased rate of setting
    (d) increased tendency for plastic shrinkage cracking
    (e) decreased long-term strength
    (f) increase tendency for drying shrinkage and cracking

    l .
    .l.
    (g) increased tendency for differential thermal effects with consequent cracking

    rw
    (h) decreased durability from cracking where there is increased permeability.

    15.1.5 Submittals

    1 ta
    The Contractor shall prepare weekly in advance his proposed concreting programme
    qa
    showing the quantities to be placed and the anticipated placing hours.

    2 At least one month before the start of the hot weather period the Contractor shall submit his
    as

    specific proposals for the control of the concrete temperature for the constituent materials;
    cement, water aggregates.
    se

    3 Where required the Contractor shall submit to the Engineer his proposals for the use of liquid
    er

    nitrogen for cooling which shall include details of previous project application and the
    intended methods to be used and quantities of liquid nitrogen.
    ov

    15.2 PLACING TEMPERATURE


    it o

    1 This Subpart of the specification applies at all times of the year and at all times of the day.
    et

    2 Maximum fresh concrete temperature (at placement) shall not exceed 32C unless
    m

    construction testing to verify a proposed concrete mixture will function satisfactorily at a


    concrete temperature greater than 32C. No concrete shall be placed if the concrete
    temperature is above 35C

    3 Concrete shall not be placed if the shade temperature exceeds 40C.

    4 The temperature of each truck of concrete shall be measured using either a glass, dial type
    or electronic thermometer, just before the placing of the concrete and the temperature
    recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire
    load of concrete in the truck or conveyer.

    5 The Contractor shall allow for the increase in concrete temperature in the period from
    dispatch from the plant while in transportation or whilst awaiting placement on Site and take
    adequate measures to ensure the maximum temperature is not exceeded.
    QCS 2014 Section 05: Concrete Page 4
    Part 15: Hot Weather Concreting

    15.3 PLANNING CONCRETING

    1 During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall
    plan concreting operations such that no concreting takes place between the hours of
    10:00 hours and 17:00 hours.

    2 The Contractor shall arrange concrete pours such that the programme of works can be
    achieved without concreting during the period from 10:00 hours to 17:00 hours.

    3 The Contractor shall nominate one member of his staff to be the co-ordinator for the supply
    of concrete. The co-ordinators responsibilities shall include ensuring the batched rate
    matches that of delivery and placement and the preparations needed before commencing a
    concrete pour.

    .
    15.4 MIX DESIGN

    l
    .l.
    1 In the hot weather period, the Contractor shall review all concrete mix designs to ensure that

    rw
    the design slump or workability specified is achieved without increase in the mix water
    content. The Contractor shall make modifications to the mix design to allow for increased
    slump loss during transportation in hot weather.
    ta
    qa
    2 This shall be achieved by adjusting the proportion of admixture, plasticiser or super
    plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix
    design with nominal values for cold weather and hot weather use.
    as

    3 Under no circumstances will the addition of extra water that increases the water cement ratio
    se

    be permitted during hotter weather.


    er

    4 All concrete materials and proportions used in periods of hot weather shall be those that have
    a satisfactory record of use in such conditions.
    ov

    15.5 TEMPERATURE CONTROL


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    15.5.1 General
    et

    1 The Contractors specific proposals for the control of the concrete temperature shall include
    m

    extent and type of shading of aggregates, method of chilling mix water and procedures for
    batching and mixing, transportation, placing and finishing, curing and protection.

    2 These shall include calculations in accordance with ACI 305R, clause 3.1 estimating
    concrete temperature. The Contractor shall calculate the temperature of freshly produced
    concrete based on the input temperatures of the constituent materials and the weights from
    particular mix designs. The calculations shall make allowance for the rise in temperature
    between mixing and placing due to the transportation and waiting period. The calculations
    shall successfully demonstrate that the temperature can be maintained below 32 C at the
    point of placing.

    15.5.2 Aggregates

    1 All practical means shall be employed to keep the aggregates as cool as possible.
    QCS 2014 Section 05: Concrete Page 5
    Part 15: Hot Weather Concreting

    2 Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond
    the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is
    not incident on the aggregates. Shades shall be constructed to allow access for mechanical
    shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit
    the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool
    the aggregate.

    3 Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall


    not be permitted.

    15.5.3 Water

    1 Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.

    2 The water shall be chilled by the use of proprietary chillers or the addition of ice to the water

    l .
    tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited

    .l.
    directly into the mixer.

    rw
    3 Water shall not be chilled below a temperature of 5 C.

    4
    ta
    Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and
    painted white.
    qa
    5 The mechanical refrigeration equipment and insulated water storage shall be adequate for
    as

    the anticipated hourly and daily production rates of concrete during the hot weather period.
    se

    6 Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank,
    such procedures shall be to the approval of the Engineer.
    er

    7 Ice shall be completely melted in mixing water prior to adding water to the mixer.
    ov

    15.5.4 Cement
    o

    1 The use of freshly ground cement at very high temperatures is not permitted.
    it
    et

    2 The cement shall be kept below the temperature which there is a tendency of false set.
    m

    3 Under no conditions shall the temperature of the cement exceed 75 C when it enters the
    mixture.

    4 The Contractor shall make arrangements for storage on Site to allow cooling of freshly
    ground and delivered cement.

    15.5.5 Addition of Ice

    1 Crushed shaved or chipped ice can be used as part of the mixing water for reducing the
    concrete temperature.

    2 The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted
    before the completion of mixing of the concrete in the pan.

    3 To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of


    the batch water requirement.
    QCS 2014 Section 05: Concrete Page 6
    Part 15: Hot Weather Concreting

    4 Crushed ice shall be stored at a temperature that will prevent lumps from forming by
    refreezing of particles.

    5 The batching plant shall incorporate a mechanical system for correctly proportioning and
    weighing the ice to be added to the mixture.

    6 The quantity of ice shall be deducted from the total batch water.

    7 The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated
    storage on the Site at the plant to meet the anticipated daily and hourly production rates of
    concrete during the hot weather period.

    15.5.6 Liquid Nitrogen

    1 Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

    l .
    .l.
    2 Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not

    rw
    frozen.

    3 The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and

    ta
    injection facility for the batching plant or one or more injection stations for truck mixers.
    qa
    4 The system may be set up at the Site for injection just before placing.

    5 Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.
    as

    15.6 BATCHING AND MIXING


    se

    1 The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.
    er
    ov

    2 Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with
    water and the drum flushed out with cold water before batching. Care shall be taken to
    ensure all water is removed from the drum before batching.
    it o

    3 The temperature of the concrete shall be checked after discharge from the mixer and written
    et

    on the delivery ticket. Temperature check shall be carried out at the plant on the concrete
    3
    floor for every 50 m produced or every hour which ever is the minimum.
    m

    4 A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN


    480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature
    conditions.

    15.7 TRANSPORTATION

    1 The transportation, placing, compaction and finishing of concrete shall be at the fastest
    possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of
    placement and compaction.

    15.8 PLACING AND FINISHING

    1 If the temperature of the first truck of concrete of a particular pour is above the specification
    maximum temperature limit then placing shall not commence.
    QCS 2014 Section 05: Concrete Page 7
    Part 15: Hot Weather Concreting

    2 If a pour is in progress and the temperature of a particular truck exceeds the maximum
    permitted temperature the placing may be allowed to continue at the discretion of the
    Engineer in order to avoid the possible development of a cold joint.

    3 However, no further concreting pours shall take place until the Contractor has submitted
    revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the
    maximum temperature will not be exceeded in the future. Before beginning new pours the
    temperature of the concrete constituent materials shall be monitored to verify that they meet
    the assumptions of the calculations.

    15.9 CURING AND PROTECTION

    1 Curing and protection shall conform to the requirements of Part 10 of this Section.

    2 Evaporation shall be minimised, particularly during the first few hours subsequent to placing

    l .
    concrete, by suitable means such as applying moisture by fog spraying or any other means

    .l.
    acceptable to the Engineer.

    rw
    15.10 INSPECTION AND TESTING

    1
    ta
    All thermometers used for the measurement of concrete temperature shall be calibrated
    qa
    weekly against a glass mercury thermometer. Calibration shall be carried out over the
    temperature range of 10 C to 100 C using a water bath with ice or heating.
    as

    2 The method used to determine acceptance of temperature controlled concrete should be in


    accordance with ASTM C1064.
    se

    3 All concrete test specimens for strength or other purposes shall be carefully protected and
    er

    cured.
    ov

    4 Specimens shall be protected from accidental damage by plant personnel or equipment on


    Site.
    o

    5 Specimens shall be kept moist by the addition of water or covering by suitable curing
    it

    materials.
    et
    m

    6 The exact time of preparation of the specimen on Site shall be noted and the time when it is
    transferred to the laboratory. These times shall be written on the test report.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 16: Miscellaneous

    16 MISCELLANEOUS .................................................................................................. 2
    16.1 GENERAL ............................................................................................................... 2
    16.1.1 Scope 2
    16.1.2 References 2
    16.2 PAVEMENT QUALITY CONCRETE ........................................................................ 3
    16.2.1 Scope 3
    16.2.2 Mix Designs 3
    16.2.3 Cement 4
    16.2.4 Water 4
    16.2.5 Aggregates 5
    16.2.6 Admixtures 5
    16.2.7 Air content 5

    .
    16.2.8 Density 5

    l
    .l.
    16.3 CEMENTITIOUS GROUT ........................................................................................ 6

    rw
    16.3.1 General 6
    16.3.2 Material 6
    16.3.3 Workmanship 6
    16.4 ta
    SCREEDS ............................................................................................................... 7
    qa
    16.4.1 Scope 7
    16.4.2 General 7
    as

    16.5 CELLULAR CONCRETE ......................................................................................... 9


    16.6 REPAIR OF CONCRETE ........................................................................................ 9
    se

    16.6.1 General 9
    16.6.2 Honeycombing or Spalling 9
    er

    16.6.3 Crack injection 11


    ov

    16.7 POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NON-


    PRESSURE DRAINAGE AND SEWERAGE ......................................................... 13
    o

    16.7.1 General 13
    it

    16.7.2 Resin 13
    et

    16.7.3 Minimum strength 14


    m
    QCS 2014 Section 05: Concrete Page 2
    Part 16: Miscellaneous

    16 MISCELLANEOUS

    16.1 GENERAL

    16.1.1 Scope

    1 This Part deals with miscellaneous items related to concrete works including pavement
    quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair
    of concrete and guniting.

    2 Related Sections and Parts are as follows:


    This Section
    Part 2, .............. Aggregate

    l .
    Part 3, .............. Cementitious Material

    .l.
    Part 4, .............. Water

    rw
    Part 5, .............. Admixture
    Part 6, .............. Property Requirements
    Part 7, .............. Concrete Plants

    ta
    Part 8, .............. Transportation and Placing of Concrete
    Part 9, .............. Formwork
    qa
    Part 10, ............ Curing
    Part 15, ............ Hot Weather Concreting.
    as

    16.1.2 References
    se

    1 The following standards are referred to in this Part:


    er

    ACI 506, .....................Guide to Shotcrete


    ASTM C989 10, ........Standard Specification for Slag Cement for Use in Concrete and
    ov

    Mortars
    BS 146,.......................Portland-blast furnace cement
    o

    BS 812,.......................Testing aggregates
    it

    BS 1881,.....................Testing concrete
    et

    BS 2782,.....................Methods of testing plastics


    m

    BS 3892,.....................Pulverised fuel ash


    BS 4551,.....................Methods of testing mortars, screeds and plasters
    BS 5075,.....................Concrete admixtures
    BS 6319,.....................Testing of resin and polymer / cement compositions for use in
    construction
    BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement.
    BS 8203,.....................Code of practice for installation of resilient floor coverings.
    BS 8500,.....................Concrete
    BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for
    common cements
    BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2,
    4, 5, 6, 8, 10, 11, and 12)
    BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6)
    BS EN 998,.................Specification for mortar for masonry
    QCS 2014 Section 05: Concrete Page 3
    Part 16: Miscellaneous

    BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis


    BS EN 12350,.............Testing fresh concrete
    BS EN 12390-5, .........Flexural strength of test specimens
    BS EN 12620,............. Aggregates for concrete

    EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low


    early strength blastfurnace cements
    EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low
    early strength blastfurnace cements
    EN 12350, ..................Testing fresh concrete
    EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis
    GSO EN 206-1, ..........Concrete Specification, performance, production and conformity

    .
    SHW 1000 ..................Specification for Highway Works UK ROAD PAVEMENTS

    l
    .l.
    CONCRETE MATERIALS

    rw
    16.2 PAVEMENT QUALITY CONCRETE

    16.2.1 Scope
    ta
    qa
    1 This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as
    surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement
    bound granular material used as a roadbase or sub-base or as a backfill material for
    as

    excavations.
    se

    16.2.2 Mix Designs


    er

    1 Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1
    below, in accordance, with the pavement design shown on the Drawings or as directed by the
    ov

    Engineer.
    o

    2 All concrete for use in pavements shall be designed mixes or equivalent standard mixes in
    it

    accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where
    et

    otherwise specified.
    m

    3 Prescribed mixes may be used for rapid construction with the approval of the Engineer.

    Table 16.1
    Pavement Grades
    BS 8500 and
    BS 8500 and
    GSO EN 206-
    Pavement Layer GSO EN 206-1
    1Designed
    Standard Mix
    Mix
    Surface Slabs
    Unreinforced Concrete C40
    Jointed Reinforced Concrete ( JRC ) C40
    Continuously Reinforced Concrete Pavement ( CRCP ) C40
    Continuously Reinforced Concrete Roadbase ( CRCR ) C40
    Ground Anchorage Beam C40
    QCS 2014 Section 05: Concrete Page 4
    Part 16: Miscellaneous

    BS 8500 and
    BS 8500 and
    GSO EN 206-
    Pavement Layer GSO EN 206-1
    1Designed
    Standard Mix
    Mix

    Wet Lean Mix Concrete 4 C20 ST4


    Wet Lean Mix Concrete 3 C15 ST3
    Wet Lean Mix Concrete 2 C10 ST2
    Wet Lean Mix Concrete 1 C7.5 ST1

    16.2.3 Cement

    1 The general term 'cement' in this Part means the materials shown below.

    l .
    .l.
    Cement Complying with

    rw
    Cement. Composition, specifications and conformity criteria for EN 197-1
    common cements
    Portland blast furnace cement BS 146 or EN 197-4

    ta
    Specification for pozzolanic pulverised-fuel ash cement (grades BS 6610
    qa
    C20 or below)
    as

    2 The use of a combination of Portland cement and ground granulated blast furnace slag is
    permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate
    the minimum combined cementitious material content required for the mix.
    se

    3 The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted
    er

    subject to the approval of the Engineer. In such cases, the Engineer will stipulate the
    ov

    minimum combined cementitious material content required for the mix. PFA shall be in
    accordance with BS 3892.
    o

    4 The use of microsilica in the mix designs will be permitted if approved by the Engineer.
    it
    et

    5 The Engineer will stipulate the minimum combined cementitious material content required for
    the mix where PFA or GGBFS are used.
    m

    6 The maximum proportion of ground granulated blastfurnace slag with Portland cement shall
    be as per Table 6.6 of Part 5.6.

    7 In combination with Portland cement, the proportion of PFA by mass to the total cement shall
    be as per Table 6.6 of Part 5.6.

    8 The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.

    9 The minimum cement content for concrete pavements shall be preapproved by Qatar
    Standards.

    16.2.4 Water

    1 Water for use in the making and curing of concrete shall conform to the requirements of Part
    4 of this Section.
    QCS 2014 Section 05: Concrete Page 5
    Part 16: Miscellaneous

    2 The water content shall be the minimum required to provide the agreed workability for full
    compaction of the concrete to the required density, as determined by trial mixes or other
    means approved by the Engineer..

    16.2.5 Aggregates

    1 The requirements of Part 2 of this specification will govern, except as modified below.

    2 Aggregates for all pavement concrete shall be complying with BS EN 12620

    3 Alternatively coarse aggregate of recycled and secondary aggregate materials may be used
    to replace up to 50% by mass of coarse aggregate

    4 The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between
    longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not

    l .
    exceed 20 mm.

    .l.
    rw
    5 If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate
    combination to check for the possibility of alkali silica reaction. Such tests shall be carried out
    in accordance with the procedure laid down in Part 2 of this Section.

    16.2.6 Admixtures ta
    qa
    1 Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN
    as

    934. Admixtures containing calcium chloride shall not be used.

    2 Other chloride-free admixtures may be used with the approval of the Engineer.
    se

    16.2.7 Air content


    er
    ov

    1 The total quantity of air in air-entrained concrete as a percentage of the volume of the mix
    shall be 5 1.5 % for mixes of nominal aggregate size 20 and be 4 1.5 % for mixes of
    nominal aggregate size 40.
    it o

    2 The air content shall be determined at the point of delivery by a pressure type air meter in
    et

    accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at
    least six times per day whichever is the greater, in conjunction with tests for workability and
    m

    strength. For areas less than 300 m2, the rate shall be at least one determination to each 20
    m length of slab or less constructed at one time or at least three times per day. If the air
    content is outside the specified limits, a further determination shall be made immediately on
    the next available load of concrete before discharging. If the air content is still outside the
    limit, the Contractor shall immediately adjust the air content of the concrete to improve its
    uniformity, before further concrete is used in the Works.

    3 The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing
    the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure
    uniform distribution of the agent throughout the batch during mixing.

    16.2.8 Density

    1 The density of concrete Grades greater than C30 shall be such that without air-entrainment
    the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not
    more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.
    QCS 2014 Section 05: Concrete Page 6
    Part 16: Miscellaneous

    2 The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the
    theoretical maximum dry density.

    16.3 CEMENTITIOUS GROUT

    16.3.1 General

    1 This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be
    used to where it is necessary to eliminate shrinkage when filling the void between a base
    plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including
    masts, anchor bolts and fence posts.

    2 The grout shall be supplied by a reputable construction chemical company as a single pack
    prepackaged cement based product which is chloride free.

    l .
    3 For a particular application, the Contractor shall submit a method statement detailing how the

    .l.
    formwork will be placed and the points where the grout will be poured.

    rw
    4 Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of
    the materials and methods with the suppliers representative being present to train the

    ta
    Contractors personnel in the correct use of the material.
    qa
    16.3.2 Material
    as

    1 The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing
    and non shrink.
    se

    2 Positive volumetric expansion shall take place while the grout is plastic by means of gaseous
    er

    expansion to avoid shrinkage and cracking.


    ov

    3 The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall
    be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.
    o

    4 The grout shall exhibit a high early strength gain yet not be subject to cracking or other
    it

    detrimental effects.
    et

    5 At ambient temperatures above 35 C, cool water shall be used for mixing the grout before
    m

    placing.

    16.3.3 Workmanship

    1 The storage handling and pouring of the grout shall be in strict accordance with the
    manufacturers instructions.

    2 The substrate surface shall be free from oil grease or loose or partially bonded material.

    3 If the concrete surface is defective or has laitance it shall be cut back to a sound base.

    4 Bolt holes and fixing pockets shall be blown clean of dirt or debris.

    5 The substrate shall be soaked with fresh potable water before grouting, although immediately
    before grouting, free water shall be removed and blown out of bolt holes or pockets.
    QCS 2014 Section 05: Concrete Page 7
    Part 16: Miscellaneous

    6 Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide.
    For larger base plates or flow areas the manufacturers instructions shall be followed.

    7 Base plates and metallic items shall be clean and free from oil, grease, or scale.

    8 Vent holes shall be provided to allow the release of air from isolated spots.

    9 Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between
    the constructive formwork and joints. Formwork shall extend above the required pour height
    and if necessary shall be extended to allow a hydrostatic head to aid placement.

    10 The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.

    11 The quantity of water to be added to the preweighed bags shall be enough to give the
    desirable consistency as trowelable or flowable.

    l .
    .l.
    12 Mixing shall take place for a minimum of 5 min.

    rw
    13 The grout shall be placed within the time limit specified by the manufacturer depending on
    the actual application temperature.

    14 ta
    Grout shall be poured from one side and it shall be verified that the grout has flowed under all
    qa
    of the base plate with no voids. Pouring from several sides shall not be permitted.

    15 Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.
    as

    16.4 SCREEDS
    se

    16.4.1 Scope
    er
    ov

    1 This Subpart covers screeds that provide by means of a layer of mortar a level surface in
    flooring applications and to provide falls on flat concrete roofs.
    o

    16.4.2 General
    it
    et

    1 Screeds shall be suitable for application onto a concrete substrate.


    m

    2 The screeds shall be suitable for receiving surface finishes which may arrange from thin
    flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.

    3 Screed mortars shall generally comprise sand and cement modified by additives or
    substituted by other materials such as polymers in order to provide specific performance
    requirements.

    4 For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of


    10 mm aggregate.

    5 Aggregates used for screeds shall not contain deleterious materials such as coal or iron
    particles which may affect the finish the surface of the screed.

    6 Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening
    and shall comply with the appropriate part of BS EN 480 and BS EN 934.
    QCS 2014 Section 05: Concrete Page 8
    Part 16: Miscellaneous

    7 Polymer based additives may be used to improve adhesion and strength of thin or featured
    screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or
    acrylic polymers.

    8 Ready to use sand cement screeds shall comply with the material requirements BS EN 998.

    9 Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used
    strictly in accordance with the manufacturers instructions.

    10 The interface of the screed in the concrete substrate shall be specified as one of the
    following options by the Engineer:

    (a) Monolithic with the concrete base: The screed shall be applied within 3 hours of
    placing the concrete base.
    (b) Bonded to the concrete base: Screed shall be laid onto a concrete base which is

    l .
    hardened and is subsequently been prepared to receive the screed, the minimum

    .l.
    thickness of the screed shall be 25 mm and the maximum thickness 40 mm.

    rw
    (c) As an unbonded screed: The screed shall be laid on a separating layer.
    (d) As a floating screed: The screed shall be laid on an insulating material.

    11 ta
    The cement and sand screed mix shall have the minimum amount of water added to give
    qa
    sufficient workability and allow the material to be thoroughly compacted.
    as

    12 Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate
    ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water
    se

    and admixtures shall ensure a thorough homogeneous mixture with no balling up of the
    cement.
    er

    13 Screeds shall be laid either between carefully levelled and trued batons or between strips of
    ov

    screed laid and compacted to a finished level.

    14 For bonded screed where a high degree of bond is required the surface laitance of the
    o

    concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer
    it

    of neat cement grout shall be applied to the prewetted or dampened concrete and the screed
    et

    applied and compacted while the grout is wet.


    m

    15 Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints
    around the perimeter shall be particularly well compacted to avoid breaking out and curling.

    16 Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be
    kept protected by waterproof sheeting for at least 7 days after laying.

    17 Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and
    necessary strength achieved.

    18 If requested by the Engineer the Contractor shall carry out a soundness and impact test in
    accordance with BS 8203.

    19 Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction
    or movement joints shall be provided as appropriate, where shown on the drawings or as
    directed by the Engineer. Bays shall be laid alternatively.
    QCS 2014 Section 05: Concrete Page 9
    Part 16: Miscellaneous

    20 Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick
    screed.

    16.5 CELLULAR CONCRETE

    1 Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is


    exchanged for an insulation medium, namely air, embedded in an organic and bio-
    degradable foam. It behaves, like conventional concrete, in particular concerning curing,
    hardening and most important "ageing ". CC infinitely increases its strength by hydration as
    long as exposed to humidity in the atmosphere.

    2 CC offer more thermal insulation and a substantially higher fire-rating than conventional
    concrete.

    3 Minimum compressive strengths shall be 4.0 MPa.

    l .
    .l.
    4 The required density and strength of the CC shall be specified on the drawings and approved

    rw
    by the Engineer.

    5 The method of production of Cellular Concrete shall be shown on the drawings or directed by

    ta
    the Engineer. The Contractor shall submit full technical details of the materials and method of
    qa
    production for the CC along with a list of previous projects where the particular system has
    been used.
    as

    6 After source approval of the material and system the Contractor shall submit a mix design for
    the CLC for the approval of the Engineer. After the review and approval of the mix theoretical
    se

    mix design the Contractor shall carry out a trial mix to check the workability of the fresh
    concrete and to allow samples to be made for compressive strength and density.
    er

    7 The Engineer may also instruct that tests are carried out for abrasion resistance and thermal
    ov

    insulation properties.

    8 Cellular Concrete shall not be used for structural reinforced members.


    it o

    16.6 REPAIR OF CONCRETE


    et
    m

    16.6.1 General

    1 The extent and nature of the defects in concrete shall be established in accordance with Part
    15 of this Section. Based on these results the Engineer shall confirm the acceptability of the
    work and whether remedial works are required.

    2 If remedial works are required the Contractor shall submit a detailed method statement
    identifying the specific materials to be used and the sequence of activities for the repair.

    3 Only proprietary proven materials that form part of a standard repair system shall be used.

    16.6.2 Honeycombing or Spalling

    1 Where there is honeycombed concrete or concrete damaged by physical forces such as


    impact that has caused spalling, the concrete shall be replaced using a high strength free
    flowing cementitious micro-concrete.

    2 The areas of repair shall be marked out and agreed with the Engineer.
    QCS 2014 Section 05: Concrete Page 10
    Part 16: Miscellaneous

    3 All honeycombed, loose, cracked or friable concrete in these areas shall be removed until
    sound concrete is reached. Due account shall be taken of propping or other instructions
    given by the Engineer regarding sequences of removal and repair.

    4 The equipment and methods used to break out the concrete shall be such that no reinforcing
    steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened
    or damaged unless so directed by the Engineer.

    5 Where the removal of concrete by mechanical means is difficult due to reinforcement


    congestion, then the use of high pressure water jetting shall be considered and necessary
    provisions for protecting the rest of the structure shall be made.

    6 The prepared void shall be profiled so that entrapment of air is avoided during the repair
    process using fluid micro-concrete.

    7 The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be

    l .
    repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be

    .l.
    accepted.

    rw
    8 The prepared concrete surface shall be sound and clean and free of loose particles, dust and
    debris.

    9 ta
    Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose
    qa
    millscale.

    10 Reinforcement damaged during the removal of concrete or the preparation process shall, if
    as

    required by the Engineer, be repaired or replaced.


    se

    11 Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall
    be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair
    er

    material without distortion or movement during placement.


    ov

    12 The formwork shall be watertight at all joints between panels and between the formwork and
    the existing concrete surface so as to prevent grout leakage.
    o

    13 The formwork shall be constructed from appropriate materials as agreed with the Engineer to
    it

    achieve the required finish.


    et

    14 Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated
    m

    with a suitable mould release agent. This shall be used in accordance with the
    manufacturer's recommendations.

    15 The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient
    hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled
    completely and no air remains entrapped.

    16 Where necessary, provision shall be made for controllable bleed points to prevent air
    entrapment and enable the extent of flow of the repair material to be assessed.

    17 The formwork shall be inspected by the Engineer and, if approved, filled with clean water
    which demonstrates that the formwork is grout-tight and saturates the prepared concrete
    surfaces. The formwork shall be then be completely drained and resealed

    18 In situations where the completed repair will be subjected to constant immersion an epoxy
    bonding agent shall be applied in accordance with the manufacturers instructions.
    QCS 2014 Section 05: Concrete Page 11
    Part 16: Miscellaneous

    19 Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18
    and tested at 20 oC

    20 The thermal conductivity and the elastic modulus of the repair material shall be compatible
    with the host concrete.

    21 If requested by the Engineer, recent test results of the material for the following properties
    shall be submitted:

    (a) thermal conductivity


    (b) elastic modulus, BS 1881
    (c) expansion characteristics, ASTM C 827, CRD 621-82A
    (d) flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

    22 The micro-concrete shall be mixed and placed in accordance with the manufacturer's

    l .
    recommendations, particularly with regard to water content, mixing equipment and placing

    .l.
    time.

    rw
    23 As far as possible the placing of the micro-concrete shall be continuous. The mixing
    operation shall be timed so that there is minimal interruption in the material flow. If, however,

    ta
    placing is interrupted, the operation shall recommence as soon as possible while the repair
    material retains its flow characteristics.
    qa
    24 The formwork shall not be removed until the repair micro-concrete has achieved a
    compressive strength of at least 10 MPa or as directed by the Engineer.
    as

    25 Immediately after removal of the formwork the repair area shall be cured in accordance with
    se

    Part 10 of this Section.


    er

    26 The repair material shall:

    (a) be shrinkage compensated in both liquid and cured states


    ov

    (b) contain no metallic expansion system


    o

    (c) be prepacked and factory quality controlled


    it

    (d) be a free-flowing cementitious material that has a coefficient of thermal expansion fully
    et

    compatible with the host concrete and which complies with the requirements of Table
    16.3.
    m

    Table 16.3
    Property requirements of micro concrete

    Property Test Method Minimum Value

    Compressive strength BS EN 12390-3 @ 28 d 50 MPa


    Flexural strength BS 4551 @ 28 d 10 MPa
    Anchorage bond BS 8110 Passes

    16.6.3 Crack injection

    1 This clause of the specification covers non-active cracks within concrete elements caused by
    shrinkage or other structural movement. Non-active cracks shall be injected with a low-
    viscosity epoxy resin to fill and seal the crack and restore the structural integrity.
    QCS 2014 Section 05: Concrete Page 12
    Part 16: Miscellaneous

    2 Before to starting the injection operation it shall be established by testing and investigation
    work that cracks manifest within concrete elements due to either or both shrinkage or
    structural movement are non-active.

    3 The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be
    filled shall be marked out in detail on the concrete elements by the Contractor and agreed
    with the Engineer before proceeding.

    4 The extent of the work may be adjusted by the Engineer as the project proceeds, according
    to the conditions found.

    5 Grease, oil or other contaminants shall be removed. Algae and other biological growth shall
    also be removed by scrubbing with bactericide or detergent and clean water. If necessary,
    wire brushes shall be used.

    l .
    6 Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within

    .l.
    the marked out scope of the work shall be removed.

    rw
    7 All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the
    concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

    8 ta
    The injection nipples shall be fixed at intervals along the length of each crack. The distance
    qa
    between each nipple will depend on the width and depth of the crack.
    as

    9 Spacing shall be close enough to ensure that the resin will penetrate along the crack to the
    next point of injection. This will normally be between 200 mm and 100 mm.
    se

    10 Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant
    shall be supplied in two pans (liquid base and hardener system). The two components shall
    er

    be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.


    ov

    11 The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall
    be pressed firmly into place and held for several seconds until secure. The mixed sealant
    o

    shall be applied around each embedded nipple, ensuring a complete seal is made. In this
    it

    way, all the nipples shall be fixed along the length of the crack.
    et

    12 In the case of a wall or slab which is cracked all the way through, nipples shall be located on
    m

    both sides with those at the back placed at midway points between those it the front.

    13 The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to
    40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or
    slab shall be sealed in this way.

    14 The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures
    (5 C to 12 C) the curing time will be extended and the Contractor shall ensure that the
    surface sealant has adequately cured before continuing.

    15 One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to
    either end of horizontal cracks.

    16 Each crack shall be treated in a single, continuous operation. Sufficient material shall
    therefore be made ready before the commencement of the work.
    QCS 2014 Section 05: Concrete Page 13
    Part 16: Miscellaneous

    17 The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of
    the mixed material.

    18 The preparation, mixing and application of the materials shall be undertaken in strict
    accordance with the manufacturer's recommendations. The Contractor is to ensure that all
    necessary tools and equipment are on Site.

    19 Both the compressive strength and flexural strength shall be tested at 7 d.

    20 The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the
    failure shall be in the concrete and not at the interface.

    21 The injection resin shall be of a prepackaged or preweighed type and only the use of full units
    will be allowed. No part packs or on-Site batching will be allowed under any circumstances.

    l .
    22 In all operations of storage, mixing and application, the Contractor shall comply with the

    .l.
    health and safety recommendations of the manufacturer and governing authorities.

    rw
    23 The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this
    time.

    24 ta
    The nipples and bands of surface sealant shall then be removed and damaged areas made
    qa
    good to the satisfaction of the Engineer.

    25 The injection material shall be compatible with the host concrete and shall have the
    as

    properties shown in Table 16.4 when tested in accordance with the relevant standards.
    se

    Table 16.4
    Property Requirement for Epoxy Crack Injection Material
    er

    Property Method Minimum Value


    ov

    Compressive strength BS 4551, BS 2782 BS 6319 70 MPa


    Flexural strength BS EN 12390-5
    it o

    16.7 POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NON-


    et

    PRESSURE DRAINAGE AND SEWERAGE


    m

    16.7.1 General

    1 Polyester resin concrete is a mixture formed from aggregates and fillers which are bound
    together using a polyester resin (also called Polymer concrete pipes), as defined in ISO
    18672-1 or ASTM D 6783 with the amendments given below.

    2 Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems
    (pipes, manhalls, soakways).

    16.7.2 Resin

    1 The resin used in the pipe system and manufactured as per ISO 18672-1shall have a
    temperature of deflection of at least 85 C, when tested in accordance with Method A of
    ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the
    applicable requirements of EN 13121-1.
    QCS 2014 Section 05: Concrete Page 14
    Part 16: Miscellaneous

    2 The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a
    minimum deflection temperature of 85C when tested at 1.82 MPa following Test Method
    D648. The resin content shall not be less than 7 % of the weight of the sample as determined
    by Test Method D2584.

    16.7.3 Minimum strength

    1 The minimum strength classes for different pipe shapes are given below.
    Table 16.4

    Minimum strength classes for pipes designated PRC-OC or PRC-TC


    Strength class
    Nominal size Sc
    DN N/mm

    .
    PRC-OC PRC-TC

    l
    .l.
    150 DN 500 180 180

    rw
    600 DN 1000 145 160
    1200 DN 3000 120 145

    ta
    qa
    Table 16.5
    Minimum strength classes for pipes designated PRC-OE or PRC-TE
    as

    Strength class
    Nominal width/height Sc
    WN/HN
    se

    N/mm
    er

    PRC-OE PRC-TE
    ov

    300/450 WN/HN 600/900 180 180


    700/1050 WN/HN 1000/1500 145 160
    o

    1200/1800 WN/HN 1400/2100 120 145


    it
    et

    Table 16.6
    m

    Minimum strength classes for pipes designated PRC-OK or PRC-TK


    Strength class
    Sc
    Nominal size
    DN N/mm
    PRC-OK PRC-TK
    800 DN 1000 145 160
    1200 DN 1800 120 145

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 17: Structural Precast Concrete

    17 STRUCTURAL PRECAST CONCRETE .................................................................. 2


    17.1 GENERAL ............................................................................................................... 2
    17.1.1 Scope 2
    17.1.2 References 2
    17.1.3 Submittals 3
    17.1.4 Qualifications 4
    17.1.5 Quality Assurance 4
    17.1.6 Quality Control 5
    17.1.7 Testing 6
    17.1.8 Delivery, Storage and Handling 7
    17.1.9 Design Loadings, Actions and Structural Members Selection 7
    17.2 MATERIALS ............................................................................................................ 8

    .
    17.2.1 General 8

    l
    .l.
    17.2.2 Reinforcing Bars 8
    17.2.3 Bearing Pads 8

    rw
    17.2.4 Embedded Steel 8
    17.3 FORMING ............................................................................................................... 8
    17.3.1 General ta 8
    qa
    17.3.2 Tolerances 9
    17.4 INSTALLATION ....................................................................................................... 9
    as

    17.4.1 General 9
    17.4.2 Survey 9
    se

    17.4.3 Guying, Bracing and Shoring 9


    17.4.4 Adjustment and Correction 9
    er

    17.4.5 Erection Tolerances 10


    17.4.6 Welding 10
    ov

    17.4.7 Grouting 10
    17.4.8 Field Cutting 10
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 17: Structural Precast Concrete

    17 STRUCTURAL PRECAST CONCRETE

    17.1 GENERAL

    17.1.1 Scope

    1 The work included in this Section comprises furnishing all plant, labour, equipment,
    appliances and materials and performing all operations in connection with Structural Precast
    Concrete Work.

    2 Related Sections and Parts are as follows:

    This Section
    Part 2 ............... Aggregates

    l.
    Part 3 ............... Cementitious materials

    .l.
    Part 5 ............... Admixtures

    rw
    Part 6 ............... Property requirements
    Part 7 ............... Concrete Plants
    Part 8 ............... Transportation and placing of concrete
    Part 9 ............... Formwork
    Part 10 ............. Curing ta
    qa
    Part 11 ............. Reinforcement
    Part 15 ............. Hot weather concreting
    as

    17.1.2 References
    se

    1 The following standards and other documents are referred to in this Part:
    er

    AASHTO ....................Standard Specification for Highway Bridges, Section 25


    ov

    ACI 523.2R .................Guide for Precast Cellular Concrete Floor, Roof, and Wall Units
    ACI 533R ....................Guide for Precast Concrete Wall Panels
    o

    ACI 533.1R .................Design Responsibility for Architectural Precast-Concrete Projects


    it

    ACI 543R ....................Design, Manufacture, and Installation of Concrete Piles


    et

    ACI 550.1R-09............Guide to Emulating Cast-in-Place Detailing for Seismic Design of


    m

    Precast Concrete Structures


    ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures
    ACI 318-11 .................Building Code Requirements for Structural Concrete

    BS 8110......................The structural use of concrete.


    BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions
    BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for
    buildings

    ISO 9000, ..................Quality management systems. Fundamentals and vocabulary

    Prestressed Concrete Institute (PCI) , Manual 116


    QCS 2014 Section 05: Concrete Page 3
    Part 17: Structural Precast Concrete

    17.1.3 Submittals

    1 Manufacturer's Literature:

    (a) the Contractor shall provide copies of manufacturer's specifications and installation
    instructions for each item of proprietary material to be used, showing compliance with
    this specification. Information on equipment, embedded items and other accessories
    shall also be provided.

    2 Design Mixes:

    (a) copies of mix designs with support material


    (b) the requirements of the mix design shall be in accordance with Parts 6 and 7 of this
    Section.

    3 Product Design Criteria:

    l .
    (a) loadings for design:

    .l.
    (i) initial handling and erection stresses

    rw
    (ii) all dead and live loads as specified on the contract drawings or as required
    (iii) all other loads specified for the member where they are applicable.

    4 Product Design Calculations: ta


    qa
    (a) the design calculations shall be performed by a Structural Engineer experienced in
    precast concrete design. They shall cover all stages of handling, transportation and
    as

    erection. The design shall be carried out in accordance with the requirements of BS
    EN 1992-1-1 or relevant ACI codes, and shall be accepted by the Engineer.
    se

    (b) calculations for the design of precast members shall be supported by a statement
    explaining the principle of design and type of analysis adopted
    er

    (c) the influence of individual members in achieving the overall stability of the structure
    should be considered
    ov

    (d) computer programmes used in the designs shall be fully described and details of input
    and printout shall be presented in a manner which can be readily understood and the
    following requirements shall be met:
    it o

    (i) programme manuals and instructions to programme users shall be made


    et

    available to the Engineer upon request


    (ii) where such programme cannot be demonstrated by the Contractor to have been
    m

    fully checked or where the Engineer considers it necessary, the Contractor shall
    run such test examples as the Engineer may choose, in order to verify the
    completeness and accuracy of the programme
    (e) members that are exposed to the weather shall be designed to provide for the
    movement of components without damage, failure of joint seals, undue stress on
    fasteners or other detrimental effects when subject to seasonal or cyclic day/night
    temperature ranges
    (f) precast systems shall be designed to accommodate construction tolerances, deflection
    of other building structural members and the clearance of intended openings
    (g) calculate structural properties of framing members in accordance with BS 8110 or BS
    EN 1992-1-1, or relevant ACI codes.

    5 Shop Drawings. The Contractor shall provide the following information for the approval of the
    Engineer:

    (a) layout plans and detailed fabrication and placement drawings for each structural
    precast element
    QCS 2014 Section 05: Concrete Page 4
    Part 17: Structural Precast Concrete

    (b) shop drawings are to include the following information:


    (i) size, grade, profile and dimensions of all materials used
    (ii) connection and anchorage details
    (iii) lifting devices, locations and handling limitations
    (iv) steel reinforcement details
    (v) all openings, sleeves, inserts and other provisions in full co-ordination with all
    trades in the Contract
    (vi) identification marks.

    6 Erection Procedures:

    (a) detailed outline of sequence and methods of erection including but not limited to types,
    capacities and numbers of cranage, methods of support and transportation.

    .
    7 Fabrication Records:

    l
    .l.
    (a) A record shall be kept for every piece of precast element produced showing the

    rw
    following:
    (i) type and number
    (ii) date of pour
    ta
    qa
    (iii) concrete test results
    (iv) shop drawing reference number
    as

    (v) type and duration of curing


    (vi) date of delivery to Site
    se

    (vii) date of fixing in position.


    er

    8 Test Reports:
    ov

    (a) copies of all testing and inspection reports.

    9 Trial Panels:
    o

    (a) the Contractor shall produce trial panels in accordance with the requirements of
    it

    Part 10 of this Section.


    et

    (b) trial panels shall be retained for reference purposes for the acceptance of the
    production work.
    m

    17.1.4 Qualifications

    1 Structural precast work shall be executed by an approved specialist Subcontractor for casting
    and also for transportation, handling and erection.

    2 The Contractor may execute this work himself if he can satisfy the Engineer that he has
    sufficient experience and expertise in this field. As a minimum the Contractor shall:

    (a) provide satisfactory evidence that his tradesmen and their supervisory personnel
    engaged in such work have successful experience with work comparable to that
    shown and specified
    (b) provide details of organised quality control and testing procedures.

    17.1.5 Quality Assurance

    1 The precast concrete supplier shall have a quality assurance scheme that meets ISO 9000 or
    equivalent.
    QCS 2014 Section 05: Concrete Page 5
    Part 17: Structural Precast Concrete

    2 All work shall be performed to secure for the project homogeneous concrete having the
    required strength, surface finish, materials, durability, and weathering resistance, without
    planes of weakness or other structural defects, and free of honeycombs, air pockets, voids,
    projections, offset of plane and other defacements of concrete.

    3 No alterations or substitutions of the structural systems shown on the Drawings are permitted
    unless otherwise specified.

    4 The Contractor shall supervise and co-ordinate all phases of the structural precast concrete
    construction process and be responsible for the complete manufacturing process.

    5 All methods of manufacture and practices of handling raw materials and manufactured
    concrete shall be reviewed by the Engineer before execution of the structural precast
    concrete work, at least 14 days before the beginning of precasting work.

    6 Only materials of known quality shall be incorporated in the work.

    l .
    .l.
    7 All materials shall be properly selected, reviewed and approved by the Engineer before use,
    and maintained during shipment, storage and use.

    rw
    8 Construction systems and techniques shall be properly selected, reviewed and approved by
    the Engineer before use, and maintained throughout the complete structural precast concrete
    construction phase.
    ta
    qa
    9 Adequate spare equipment, parts, additional components and repair facilities shall be
    available for all tools and equipment.
    as

    10 Regardless of approvals by the Engineer, the Contractor shall be responsible for all materials
    and methods of structural precast concrete work.
    se

    11 If work does not meet the specified requirements, the Contractor shall at no additional cost to
    the Employer:
    er

    (a) implement removal, replacement or remedial work


    ov

    (b) revise procedures or materials to prevent recurrence of unacceptable work.


    o

    17.1.6 Quality Control


    it

    1 The Contractor shall prepare and provide his quality control programme for structural precast
    et

    concrete work with particular attention to details, pre-checking processes, procedures and
    m

    close supervision, and in particular the Contractor shall:

    (a) in order to assure that proper work is performed to prevent later corrective actions,
    assign at least one experienced supervisor full time to provide quality control for
    structural precast concrete work
    (b) the assignment will not relieve the Contractor's other quality control personnel of their
    duties relative to the quality control of the structural requirements and surface finish of
    the structural precast concrete work.

    2 The Contractor shall arrange for the training of his quality control personnel who will perform
    quality control of structural precast concrete work and whose training shall include but not be
    limited to:

    (a) materials evaluation


    (b) special mix design techniques
    (c) mix placement
    QCS 2014 Section 05: Concrete Page 6
    Part 17: Structural Precast Concrete

    (d) vibrator selection and use


    (e) formwork details formwork protection
    (f) release agent use
    (g) reinforcing steel
    (h) detailing and installation
    (i) finishing equipment and techniques
    (j) corrective procedures and protection of completed work.

    3 The Contractor's quality control personnel shall be responsible for verifying all details
    necessary to produce the final structural design objectives.

    4 The Contractor's quality control personnel shall also verify the quality of the structural precast

    .
    concrete work and guide the production of results which will be within acceptable physical

    l
    .l.
    tolerances

    rw
    17.1.7 Testing

    1
    ta
    Concrete shall be tested as specified in Part 6 of this Section.
    qa
    2 The Contractor shall:

    (a) furnish labour required to facilitate testing


    as

    (b) inform the Engineer with at least one day's advance notice when concrete is to be
    placed
    se

    (c) provide storage facilities for concrete test cubes


    er

    (d) provide material samples and access to materials as required for testing.
    ov

    3 Should the batching plant be located more than 500 meters away from the site offices, the
    Contractor shall provide suitable transport acceptable to the Engineer, for the sole use of the
    o

    Engineer's staff.
    it

    4 The Contractor shall station a qualified technician at the casting site to continuously test,
    et

    inspect and report on the following:


    m

    (a) that concrete testing is being carried out in accordance with the requirements of Part 6
    of this Section
    (b) check the following and verify conformance with specified requirements and approved
    shop drawings:
    (i) all reinforcing bars
    (ii) all embedded items
    (iii) all formwork
    (c) check all openings and provisions for co-ordination with all trades in the Contract as
    shown on approved shop drawings.

    5 The Contractor shall provide facilities and equipment for the conducting of all tests specified
    herein except for the strength test which should be carried out by an approved independent
    testing agency.
    QCS 2014 Section 05: Concrete Page 7
    Part 17: Structural Precast Concrete

    17.1.8 Delivery, Storage and Handling

    1 The structural precast elements shall be removed from the form without damaging or over
    stressing and stored or placed for transportation on a stable bed that will not allow distortion
    of the member.

    2 Separate stacked members with suitable battens and bracing.

    3 Mark each member with an identifying reference or piece mark, and the date of casting.

    4 All piece marks are to be correlated with test reports and plan layouts or erection drawings.

    5 The structural precast element shall be transported with sufficient battens, bracing, and
    supports so as to prevent over-stress by vibration or impact loadings. The Contractor shall
    submit his proposed method of transportation to the Engineer for approval.

    l .
    .l.
    6 Structural precast units shall be stored, handled and transported in a manner that will avoid

    rw
    undue strains, hair cracks, staining, or other damage.

    7 The Contractor shall deliver the units from the casting site to the project Site in accordance
    with schedule and proper setting sequence.
    ta
    qa
    8 Structural precast units shall be stored free of the ground and protected from wind or rain
    splashes.
    as

    9 The units shall be covered and protected from dust, dirt or other staining materials.
    se

    10 During fabrication, construction and after erection, the Contractor shall protect the castings to
    avoid the possibility of damage.
    er

    17.1.9 Design Loadings, Actions and Structural Members Selection


    ov

    1 The provisions of this Clause shall apply if the Contractor is responsible for the design of the
    o

    structural precast units.


    it
    et

    2 The precast elements shall be designed to withstand all loading conditions against which
    strength and serviceability must be measured.
    m

    3 Vertical loads shall include the self-weight of precast elements, floor coverings and live loads
    as indicated on the contract drawings.

    4 The wind loads shall be calculated based on the wind speed provided in Section 1 part 1
    clause 1.5.2.

    5 Account shall be taken of the loads and deformation caused by temperature and time
    dependent deformations. For such purpose 55 C temperature variation and 90 % relative
    humidity should be considered for all members, except exterior elements and facade
    o
    elements shall consider 85 C.

    6 Precast elements shall be designed in accordance with BS EN 1992-1-1 or relevant ACI


    code. Design tensile stresses should not exceed the design flexure tensile stress of concrete,
    at the particular age of the concrete.
    QCS 2014 Section 05: Concrete Page 8
    Part 17: Structural Precast Concrete

    7 Nominal cover to steel including links must meet the durability requirement of severe
    condition of exposure and to meet requirement for 2 h period of fire resistance, as provided
    for in BS EN 1992-1-1 or relevant ACI code.

    8 Total deflection of precast elements should be limited to 1/350 of the span of this element.

    9 Plan and design for openings for building services, where required or necessary.

    17.2 MATERIALS

    17.2.1 General

    1 The Contractor shall obtain cement, aggregates and water from a single source, sufficient to
    complete the entire structural precast concrete work to assure regularity of appearance and
    uniformity of colour.

    l .
    .l.
    2 The Contractor shall provide all materials in accordance with and meet all applicable

    rw
    requirements of this section.

    17.2.2 Reinforcing Bars

    ta
    qa
    1 Reinforcing bars shall conform to the requirements of Part 11 of this Section

    17.2.3 Bearing Pads


    as

    1 These shall be Elastomeric neoprene, conforming to AASHTO Standard Specifications for


    se

    Highway Bridges (Section 25) with the following stipulations:

    (a) use unfactored loads for design


    er

    (b) maximum compressive stress, 0.70 MPa


    ov

    (c) maximum shear stress, 0.07 MPa


    (d) maximum shear deformation, 1/2 thickness
    it o

    (e) maximum compressive strain, 15 %


    et
    m

    17.2.4 Embedded Steel

    1 All embedded items shall be of stainless steel Grade 316L.

    17.3 FORMING

    17.3.1 General

    1 Forms and casting beds are to be firmly seated so as not to deflect or be displaced under
    concreting or tensioning loads.

    2 Correct for thermally induced strains or forces.

    3 For member penetrations larger than 150 mm, coring or field cutting is not permitted unless
    approved by the Engineer.

    4 Clean and coat forms with release agent before installation or reinforcing or embedments.
    QCS 2014 Section 05: Concrete Page 9
    Part 17: Structural Precast Concrete

    17.3.2 Tolerances

    1 Permissible deviations of formed surfaces are not to exceed tolerances outlined in PCI
    Manual 116, with items as summarised or modified in Table 17.1

    Table 17.1
    Tolerances for Structural Precast Concrete

    Description Tolerance
    Dimensions
    Length: 5 mm
    Width: 3 mm

    .
    Stem 3 mm; Flange 2.0 mm.

    l
    Thickness:

    .l.
    Embedment or penetration location: 0.2 %

    rw
    Straightness: 3 mm. for 300 cm
    End squareness: 3 mm

    ta
    qa
    17.4 INSTALLATION

    17.4.1 General
    as

    1 The Contractors erection responsibilities include the safe and proper placing, aligning, and
    se

    levelling of the structural precast elements on the accepted bearing surfaces and affecting
    their proper fastening.
    er

    17.4.2 Survey
    ov

    1 Before placement of the structural precast elements the Contractor shall survey and maintain
    all temporary supports shown or required to control alignment, and deflection.
    it o

    2 Temporary supports shall be retained until framing elements braced thereby have attained
    et

    integral stability in accordance with the design.


    m

    17.4.3 Guying, Bracing and Shoring

    1 The Contractor shall install in proper sequence and maintain all temporary supports shown or
    required to control alignment, deflection and stress levels.

    2 Temporary supports shall be retained until framing elements braced thereby have attained
    integral stability in accordance with the design.

    17.4.4 Adjustment and Correction

    1 The Contractor shall compensate and correct for the misaligning affect of temperature, draw
    from welding, bolting or erection sequence or grouting.
    QCS 2014 Section 05: Concrete Page 10
    Part 17: Structural Precast Concrete

    17.4.5 Erection Tolerances

    1 The following erection tolerances shall apply unless otherwise specified in the Contract:

    (a) Variations from plumb 6 mm in 6 m run;


    12 mm total in a12 m or longer run
    (b) Variation from level or elevation 6 mm in runs;
    12 mm in 12 m run; maximum 12 mm at
    single locations
    (c) Variation from position in plan 12 mm maximum.
    (d) Offsets in alignment of adjacent
    members at joints 1.5 mm in 3 m run, 6 mm maximum.

    l .
    .l.
    17.4.6 Welding

    rw
    1 Where permission for welding is given by the Engineer, the following shall apply:

    (a)
    ta
    welding shall not take place until all adjacent elements to be connected have been
    qa
    aligned, firmly seated and braced
    (b) control of heat build-up by limiting voltage, electrode size, and rate
    as

    (c) spalled or heat damaged concrete around weldments shall not be acceptable.
    se

    17.4.7 Grouting

    1 Joints, gaps and connections shall be filled with grout as shown on the Drawings and as
    er

    approved by the Engineer.


    ov

    17.4.8 Field Cutting


    o

    1 Field cutting of holes may be done only with the Engineer's concurrence, and only with power
    it

    saws or core drills. Steel reinforcement or prestressing strand shall be avoided, where the
    et

    reinforcement or strand is damaged the unit shall be repaired to the satisfaction of the
    Engineer, or rejected.
    m

    2 The maximum hole size shall be 150 mm diameter or as limited by member size or strand
    location

    3 Any cracks, spalls and sharp corners created by field cutting are to be ground, eased, and
    patched with epoxy type bonding and patching compounds.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 18: Prestressed Concrete

    18 PRESTRESSED CONCRETE ................................................................................. 2


    18.1 GENERAL ............................................................................................................... 2
    18.1.1 Scope 2
    18.1.2 References 2
    18.1.3 Submittals 3
    18.1.4 Storage and Handling 3
    18.2 PRESTRESSING .................................................................................................... 3
    18.2.1 General 3
    18.2.2 Wires and Strands 4
    18.2.3 Sheaths, Cores and Ducts 5
    18.2.4 Anchorages 5
    18.2.5 Jacking Equipment 5

    .
    18.2.6 Tensioning 6

    l
    .l.
    18.2.7 Grouting 7
    18.2.8 Grout Mixer 7

    rw
    18.2.9 Grout Trials 8

    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 18: Prestressed Concrete

    18 PRESTRESSED CONCRETE

    18.1 GENERAL

    18.1.1 Scope

    1 This section describes the requirements for prestressed post-tensioned concrete, including
    materials and procedures for installation, stressing and grouting.

    2 Related Sections and Parts are as follows:


    This Section
    Part 2 ............... Aggregates
    Part 3 ............... Cementitious Material

    l .
    Part 4, ........... Water

    .l.
    Part 5, ........... Admixtures

    rw
    Part 6, ............ Property requirements
    Part 7, ........... Concrete Plants
    Part 8, ............ Transportation and placing of concrete
    Part 9, ........... Formwork
    Part 10, ........... Curing ta
    qa
    Part 11, ........... Reinforcement
    Part 15, ........... Hot weather concreting
    as

    Part 16, ........... Miscellaneous

    18.1.2 References
    se

    ACI 325.7R ------------- Recommendations for Designing Prestressed Concrete Pavements


    er

    ACI 343R ---------------- Analysis and Design of Reinforced Concrete Bridge Structures
    ACI 350.3R ------------- Seismic Design of Liquid-Containing Concrete Structures
    ov

    ACI 358.1R ------------- Analysis and Design of Reinforced and Prestressed-Concrete


    Guideway Structures
    ACI 372R ---------------- Design and Construction of Circular Wire- and Strand-Wrapped
    o

    Prestressed-Concrete Structures
    it

    ACI 373R ---------------- Design and Construction of Circular Prestressed Concrete Structures
    with Circumferential Tendons
    et

    ACI 423.3R ------------- Recommendations for Concrete Members Prestressed with Unbonded
    m

    Tendons

    ASTM A881/A881M -- Standard Specification for Steel Wire, Deformed, Stress-Relieved or


    Low-Relaxation for Prestressed Concrete Railroad Ties
    ASTM A882/A882M--- Standard Specification for Filled Epoxy-Coated Seven-Wire
    Prestressing Steel Strand
    ASTM A641/A641M Standard Specification for Zinc-Coated (Galvanized) Carbon Steel
    Wire
    ASTM A416/A416M-10 Standard Specification for Steel Strand, Uncoated Seven-Wire for
    Prestressed Concrete

    AWWA D110-------------Wire- and Strand-Wound, Circular, Prestressed Concrete Water


    Tanks

    BS 1881......................Testing Concrete.
    BS EN 12350,.............Testing fresh concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 18: Prestressed Concrete

    BS EN 12390,.............Testing hardened concrete


    BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing
    of concrete.
    BS EN 1992 Eurocode 2: Design of concrete structures
    GSO ISO 1920, .......... Testing of concrete

    18.1.3 Submittals

    1 Samples
    (a) a 1 m length sample of strand shall be taken from every 1000 m of strand to be
    installed in the works with a minimum of one sample of strand per reel, on Site in the
    presence of the Engineer for strength test at an independent laboratory approved by
    the Engineer. A reel shall only be accepted if both the breaking load and the 0.1 %
    proof load of the sample exceed the characteristic load given in BS 5896 Table 6

    .
    (b) a minimum of three samples of strand shall be taken at random from each reel of

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    prestressing steel on Site in the presence of the Engineer. The reels on Site shall only

    .l.
    be accepted if the relaxation values determined by the tests are equal to or lower than

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    the specified relaxation class of BS 5896.
    (c) Sample requirements and frequency for prestressing wire shall meet the requirements
    of AWWA D110 and ACI 372R.
    2
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    Technical details of the proposed materials and equipment shall be submitted. Details of the
    jack type and size shall be submitted to allow for clearances to be checked. A calibrated
    qa
    stress-recording device shall be used. Design Data. The Contractor shall submit:

    (a) details of the proposed grout mix design


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    (b) tendon extension calculations


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    (c) vent pipe spacing and location details.


    (d) detailed execution and shop drawings
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    (e) calculation notes


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    3 Other Submittals. The Contractor shall also submit:

    (a) Curriculum vitae and experience record of the supervisor proposed, who shall have a
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    minimum of five years experience in such a position


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    (b) Safety procedures, including warning signs, barricades and communication between
    et

    different stressing locations


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    (c) The name of the proposed the prestressing company, giving details of previous
    projects.

    18.1.4 Storage and Handling

    1 Prestressing steel shall be stored on palettes at least 300 mm above the ground, and be
    protected from contamination by wind blown sand or rain.

    2 Prestressing strand shall be in coils of sufficiently large diameter to ensure that the strand
    pays off straight.

    18.2 PRESTRESSING

    18.2.1 General

    1 Prestressing operation shall be carried out only under the direction of an experienced and
    competent supervisor and all personnel operating the stressing equipment shall have been
    properly trained in its use.
    QCS 2014 Section 05: Concrete Page 4
    Part 18: Prestressed Concrete

    2 In addition to the normal precautions against accident, which should be taken at all times for
    the whole of the Works, special care shall be taken when working with or near tendons which
    have been tensioned or are in the process of being tensioned.

    3 The system of prestressing used shall be a system approved by the Engineer. Such system
    shall be used strictly in accordance with the recommendations of the system manufacturer.

    4 Under no circumstances shall equipment or fittings designed for use with one system of
    prestressing be used in conjunction with equipment and fittings designed for use with another
    system.

    5 Prestressing components shall be stored in clean dry conditions. They shall be clean and
    free form loose rust and lose mill scale at the time of fixing in position and subsequent
    concreting. Slight rusting of the steel, which can be removed by moderate rubbing, is
    acceptable, but the surface shall not show signs of pitting.

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    18.2.2 Wires and Strands

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    1 All prestressing strands shall be seven-wire super stabilised low relaxation strands with a
    Guaranteed Ultimate Tensile Strength (GUTS) of not less than 1770 MPa, complying with BS
    5896 or relevant ASTM standards.
    ta
    qa
    2 All prestressing wire shall be cold-drawn, high-carbon wire meeting the requirements of
    ASTM A821/A821M, Type B having a minimum ultimate tensile strength of 1,448 MPa
    as

    (210,000 psi) prior to galvanizing. Zinc coating for galvanizing shall meet the requirements of
    ASTM A641/A641M, with a minimum weight per unit area of uncoated wire surface of 259
    se

    g/m2 (0.85 oz/ft2). The minimum ultimate strength of the wire after galvanizing shall be no
    less than 1,241 MPa (180,000 psi).
    er

    3 All wires or strands to be stressed at the same time shall be taken from the same parcel. The
    ov

    coil numbers of the steel used for each tendon shall be recorded.

    4 Welding of tendons shall not be permitted.


    it o

    5 All cutting of strands shall be carried out using a high-speed abrasive cutting wheel or friction
    et

    saw at not less than one diameter from the anchor. Cutting shall take place only after the
    Contractor has submitted the stressing records and the Engineer has approved them in
    m

    writing. Flame cutting will not be permitted.

    6 Tendons shall be built into the Works strictly in accordance with the system which is being
    employed.

    7 Sufficient strand shall project from the anchorage to allow jacking to take place at the
    stressing end of the tendon.

    8 The cable (tendons) or individual strands comprising the cable shall not be kinked or bent.
    No strand that has become unravelled shall be used.
    QCS 2014 Section 05: Concrete Page 5
    Part 18: Prestressed Concrete

    18.2.3 Sheaths, Cores and Ducts

    1 Sheaths shall be accurately located both vertically and horizontally as described in the
    Specific Project Specification. Unless otherwise described in the Specific Project
    Specification the tolerance in the location of the centre line of the sheath shall be within
    5 mm.

    2 All sheaths and cores shall be maintained in their correct positions during the placing of the
    concrete. Unless otherwise agreed with the Engineer, sheaths shall be rigidly supported at
    points not less than 50 mm and not more than 500 mm apart. The method of support shall be
    to the approval of the Engineer.

    3 Where sheaths are used, the number of joints shall be kept to a minimum and sleeve
    connectors shall be used for jointing. Each joint shall be adequately sealed against the
    ingress of material. Joints in adjacent sheaths shall be staggered by at least 300 mm

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    4 Sheaths shall be kept free of matter detrimental to the bond between the grout and the

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    sheath and, except for material sealing a sheath joint, between the sheath and concrete.

    5 Within 24 hours of the concrete being placed the Contractor shall satisfy the Engineer that

    ta
    the tendons are free to move if they are in ducts or that the ducts are free from obstruction.
    qa
    6 The number and position of grout vents for entry and outlet points and for checking that the
    entire length of duct has been adequately grouted, shall be agreed with the Engineer before
    as

    the ducts are formed.


    se

    7 Vents shall be provided at low points in the tendon profile to allow the disposal of water that
    may have collected as a result of rain or curing, for example. The vents shall be sealed
    er

    before grouting operations beginning.


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    18.2.4 Anchorages

    1 Anchorages, end blocks and plates shall be positioned and maintained in position during
    o

    concreting so that the centre line of the duct passes axially through the anchorage assembly.
    it
    et

    2 All bearing surfaces shall be clean before concreting and tensioning.


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    3 Anchoring of prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.

    18.2.5 Jacking Equipment

    1 All jacking equipment used for stressing operations shall be of the type applicable to the
    system adopted.

    2 Jack and pumps shall be calibrated at an independent facility, in the presence of the
    Engineer, before beginning stressing operations. Calibration of the equipment shall take
    place at six-month intervals for equipment permanently present on Site. Whenever new
    equipment is brought to the Site, or equipment is removed and returned, or serviced,
    recalibration of the equipment as described will be required.

    3 All gauges, load cells, dynamometers and other devices used for measurement shall have a
    reading accuracy of within 2 %.

    4 Stressing equipment for prestressing wires shall meet the requirements of AWWA D110 and
    ACI 372R.
    QCS 2014 Section 05: Concrete Page 6
    Part 18: Prestressed Concrete

    18.2.6 Tensioning

    1 The Contractor shall submit details of the proposed stressing loads and stressing sequence
    to the Engineer for approval.

    2 Tensioning shall be carried out only in the presence of the Engineer or his representative
    unless permission has been granted to the contrary.

    3 The Contractor shall ensure that personnel carrying out the stressing are provided with
    particulars of the required tendon loads, order of stressing and extensions.

    4 Immediately before tensioning, the Contractor shall prove that all tendons are free to move
    between jacking points.

    5 Unless otherwise permitted in the Contract, concrete shall not be stressed until it has

    l .
    reached at least the age at which two test cubes taken from it attain the specified transfer

    .l.
    strength. The cubes shall be made and tested as described in BS 1881 , BS EN 12350, BS

    rw
    EN 12390 or GSO ISO 1920. They shall be cured in similar conditions to the concrete to
    which they relate to, and in a manner approved by the Engineer.

    6
    ta
    The friction factors assumed for the calculation of tendon extension shall be verified by on
    Site measurement of the force-extension relationship of a typical sample of installed tendons.
    qa
    7 The Contractor shall establish the datum point for measuring extension and jack pressure to
    as

    the satisfaction of the Engineer.

    8 The tendons shall be stressed at a gradual and steady rate until they attain the force
    se

    required.
    er

    9 The maximum force exerted on the shall not exceed 75 % of the GUTS of the strand. For the
    ov

    purposes of cable detensioning, where the installed strand is to be discarded the jacking
    force may be increased to 80 % GUTS.
    o

    10 The force in the tendons shall be obtained from the readings on a load cell or pressure gauge
    it

    and the extension of the tendons measured. The two readings shall conform to the limits set
    et

    by the Engineer but in all cases the force in the tendon as computed from the extension
    measurement shall be within +5 % to -2 % of the force indicated by the gauging system.
    m

    11 When stressing from one end only the pull in at the dead end shall be accurately measured
    and the appropriate allowance made in the measured extension at the live end.

    12 If the calculated and measured extensions vary from each other by more than 6 % then
    corrective action shall be taken. This may involve detensioning and retensioning of the
    tendons if required by the Engineer.

    13 When the required force, including overloads of short duration, has been applied to the
    satisfaction of the Engineer, the tendons shall be anchored. The jack pressure shall then be
    relieved in such a way as to avoid shock to the anchorage or tendons.

    14 If the pull-in of tendons at the completion of anchoring is greater than that acceptable to the
    Engineer, the tendons shall be detensioned and the tendon tensioned again.
    QCS 2014 Section 05: Concrete Page 7
    Part 18: Prestressed Concrete

    15 The Engineer may direct that the force in any tendon be tested by rejacking. This will only be
    instructed if there is doubt that the calibration of tensioning equipment is accurate. Care shall
    be exercised by the Contractor during the retensioning to ensure that the jacking load does
    not exceed more than 80 % of the GUTS of the strand.

    16 If it is necessary to crop the tendons to enable the ducts to be grouted, this shall be delayed
    as long as is practicable up to the time of grouting. In all other cases, unless otherwise
    agreed with the Engineer, the tendons shall not be cropped less than three days after
    grouting.

    17 The Contractor shall keep full records of all tensioning operations, including the measured
    extensions, pressure gauge or load cell readings and the amount of pull-in at each
    anchorage. Copies of these records, on suitable forms, shall be supplied to the Engineer
    within 24 hours of each tensioning operation.

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    18 Tensioning prestressing wires shall meet the requirements of AWWA D110 and ACI 372R

    .l.
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    18.2.7 Grouting

    1 Grouting shall take place only with the written approval of the Engineer.

    ta
    qa
    2 All ducts shall be thoroughly cleaned by means of compressed air and all anchorages shall
    be sealed before grouting.
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    3 Ducts shall be grouted as soon as practicable after the tendons in them have been stressed
    and the Engineers written permission to commence has been obtained. Grout shall be
    se

    injected in one continuous operation and allowed to flow from the vents until the consistency
    is equivalent to that being injected. The maximum time between mixing and injection shall not
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    exceed 30 min.
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    4 The ducts shall be completely filled with grout.

    5 Vents shall be sealed consecutively in the direction of flow and the injection tube sealed
    o

    under pressure until the grout has set. The filled ducts shall be protected to the satisfaction of
    it

    the Engineer to ensure that they are not subject to shock or vibration for one day.
    et

    6 Two days after grouting, the level of grout in the injection and vent tubes shall be inspected
    m

    and made good if necessary.

    7 The Contractor shall keep full records of grouting including the date each duct was grouted,
    the proportions of the grout and admixtures used, the pressure, details of interruptions and
    topping up required. Copies of these records shall be supplied to the Engineer within three
    days of grouting.

    8 Prestressing wires shall be protected against corrosion and other damage by a shotcrete
    cover coat meeting the requirements of AWWA D110 and ACI 372R

    18.2.8 Grout Mixer

    1 The grout mixer shall produce a grout of colloidal consistency. The grout injector shall be
    capable of continuous operation with a sensibly constant pressure up to 0.7 MPa and shall
    include a system of circulating or agitating the grout whilst the actual grouting is not in
    progress. All baffles to the pump shall be fitted with sieve strainers size BS 14.
    QCS 2014 Section 05: Concrete Page 8
    Part 18: Prestressed Concrete

    2 The equipment shall be capable of maintaining pressure on completely grouted ducts and
    shall be fitted with a nozzle which can be locked off without loss of pressure in the duct.

    3 The pressure gauges shall be calibrated before they are first used in the Works and
    thereafter as required by the Engineer. All equipment shall be thoroughly washed with clean
    water at least once every three hours during grouting operations and at the end of use for
    each day.

    4 The Contractor shall ensure that standby grouting equipment is available in the event of a
    breakdown.

    18.2.9 Grout Trials

    1 The Contractor shall carry out grouting trails to the satisfaction of the Engineer before actual
    grouting taking place.

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    2 Unless otherwise directed or agreed as a result of grouting trials, the grout shall:

    rw
    (a) consist only of ordinary Portland cement, water and an approved expansion agent
    (b) have a water: cement ratio as low as possible consistent with the necessary

    ta
    workability. Under no circumstances shall the water: cement ratio exceed 0.4
    qa
    (c) not be subject to bleeding in excess of 2 % after 3 h or 4 % maximum when measured
    o
    at 18 C in a covered glass cylinder approximately 100 mm diameter with a height of
    approximately 100 mm and the water shall be reabsorbed after 24 h.
    as

    3 Admixtures containing chloride or nitrates shall not be used. Other admixtures shall be used
    se

    only with the written permission of the Engineer and shall be used strictly in accordance with
    the manufacturers instructions.
    er

    4 The grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is
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    obtained.
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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 19: Testing of Water Retaining Structures

    19 TESTING OF WATER RETAINING STRUCTURES................................................ 2


    19.1 GENERAL ............................................................................................................... 2
    19.1.1 Scope 2
    19.1.2 References 2
    19.1.3 Submittals 2
    19.1.4 General 2
    19.2 TESTING ................................................................................................................. 2
    19.2.1 General 2
    19.2.2 Cleaning 3
    19.3 TESTING PROCEDURE ......................................................................................... 4
    19.3.1 Walls 4
    19.3.2 Roofs 5

    .
    19.3.3 Disposal of Water Used for Testing 5

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    QCS 2014 Section 05: Concrete Page 2
    Part 19: Testing of Water Retaining Structures

    19 TESTING OF WATER RETAINING STRUCTURES

    19.1 GENERAL

    19.1.1 Scope

    1 This Part of the specification applies to the testing of structures that are designed with the
    intention of retaining water.

    2 Related Section and Parts are as follows:

    This Section
    Part 1 ............... General
    Part 13 ............. Inspection and Testing of Hardened Concrete

    l .
    Part 14 ............. Protective Treatments for Concrete

    .l.
    19.1.2 References

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    BS 8007......................Code of Practice for Design of concrete structures for the retaining of
    aqueous liquids

    19.1.3 Submittals ta
    qa
    1 The Contractor shall record and submit to the Engineer within 24 hours the results of the
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    watertightness tests carried out.

    19.1.4 General
    se

    1 Water retaining structures shall be watertight when subjected to external groundwater


    er

    pressures or to tests as specified in this Part.


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    19.2 TESTING
    o

    19.2.1 General
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    et

    1 The Contractor shall test watertightness of water retaining structures including storage
    reservoirs and other miscellaneous structures that require to be watertight.
    m

    2 All water used for testing shall be potable or irrigation water and the Contractor shall make
    arrangements for the supply and disposal of this water.

    3 Water retaining structures shall be tested for watertightness after completion, in accordance
    with the following method or as directed by the Engineer:

    (a) the structure shall be filled with potable or irrigation water in stages not exceeding 1 m
    in 24 h held at each water level for such time as the Engineer may require. Should
    dampness or leakage occur, the water shall be drawn off and the defects remedied to
    the satisfaction of the Engineer
    (b) in the case of structures which are subdivided into individual tanks, each individual
    tank shall be tested separately. In the case of underground or partially underground
    structures, the testing shall take place before application of water proofing membrane,
    liner material or perimeter drain, filter material or backfilling is placed against the walls
    QCS 2014 Section 05: Concrete Page 3
    Part 19: Testing of Water Retaining Structures

    (c) in the case of hopper bottomed tanks, this shall be taken to mean that no material is
    placed against the vertical external walls of the tank, the sloping walls of the hopper
    bottoms of the tanks being assumed built directly against the excavation apart from the
    blinding concrete
    (d) no placing of material against the walls shall take place until the Engineer has given
    his written approval and acceptance of the water retaining structures as watertight
    (e) filling shall not take place earlier than 28 d after the casting of the final sections of the
    structure which will be stressed by the filling of the structure.
    (f) testing shall not be undertaken until the structure to be tested has been; completed
    structurally including roof, if any, and has been passed by the Engineer in writing as
    satisfactory in all respects other than watertightness, especially in regard to the final
    finish of the work
    (g) not withstanding the satisfactory completion of the seven day test, leakage, cracks,

    l .
    and damp patches and sweating visible on the outside faces of the structure shall be

    .l.
    rectified from the water face by an injection system to the approval of the Engineer

    rw
    (h) repair making the outer face only watertight wall not be accepted, this applies to bobbin
    holes also
    (i)
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    the structure shall be retested until the watertightness is approved by the Engineer.
    qa
    (j) should the structure fail a test in the above respects, the Contractor shall immediately
    take such steps as may be necessary to:
    as

    (i) ascertain the nature and positions of defects or leakage's


    (ii) empty the structure
    se

    (iii) remedy the defects in a manner approved by the Engineer, employing workers
    er

    who are specialists in this class of work


    (k) when the remedial work has been completed in the manner approved by the Engineer,
    ov

    the testing and if necessary rectification shall be repeated until a satisfactory test is
    achieved.
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    (l) if necessary, in extreme cases of lack of watertightness, the Engineer may reject the
    it

    structure or portions thereof.


    et

    19.2.2 Cleaning
    m

    1 All water retaining structures shall, on completion, be carefully cleaned of all debris, to the
    complete satisfaction of the Engineer as follows:

    (a) shall be brushed down on all internal faces with a stiff broom while still dry
    (b) all resulting debris removed
    (c) all associated reservoir pipe work shall be cleaned in accordance with the specified
    requirements
    (d) the structure shall then be flooded with approximately 75 mm of clean water
    (e) whole of internal faces shall be carefully brushed down with stiff brooms using the
    water continuously until all faces are clean
    (f) water shall then be drained off
    (g) walls and floors hosed and flushed with clean water until perfectly clean.
    QCS 2014 Section 05: Concrete Page 4
    Part 19: Testing of Water Retaining Structures

    19.3 TESTING PROCEDURE

    19.3.1 Walls

    1 After completion and cleaning of the structure and all associated pipe work, if any, the
    Contractor shall fill the structure up to the top water level and leave for a stabilising period of
    21 d in order to allow for absorption and autogenous healing to take place.

    2 Water shall be added over this period to maintain the top water level.

    3 The Contractor shall ensure that all pipes and specials are available in ample time ahead of
    testing.

    4 Two sets of evaporation trays shall be provided along with two sets of rain gauges.

    l .
    5 Levels in the trays and structure shall be made and recorded by a hook gauge with vernier

    .l.
    attachments.

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    6 Before and during testing, flows in the structure under drainage, if any, shall be monitored,
    measured and recorded.

    7 ta
    Each under drain shall be numbered and observations reported by under drain number to
    qa
    facilitate analysis of the data.
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    8 All leaks shall be repaired within one month of their detection.


    se

    9 On the twenty-second day, two shallow watertight evaporation trays of area 0.4 m2 shall be
    filled with 75 mm of water and placed to float in the structure.
    er

    10 The water level in the structure shall be recorded and the test commenced and carried out
    ov

    over the next 7 d.

    11 Readings of water levels in the structure and trays shall be made and recorded every 24 h
    o

    over this period.


    it
    et

    12 If the water level in the tank falls by more than indicated by the evaporation trays, or other
    sign of leakage occurs by the end of the test period then the Contractor shall search and
    m

    mark all areas of defect.

    13 The structure shall then be emptied and the defects made good as specified herein.

    14 After completion of remedial measures the structure shall be refilled and the test repeated.

    15 This process shall be repeated until the structure is watertight to the satisfaction of the
    Engineer.

    16 The fall of water level in the structure over the test period of 7 d, minus the fall accounted for
    by evaporation and rainfall shall not exceed 1/500 of the average water depth of the full
    structure or 10 mm whichever is less.
    QCS 2014 Section 05: Concrete Page 5
    Part 19: Testing of Water Retaining Structures

    19.3.2 Roofs

    1 The roofs of structures shall be tested for watertightness before laying of roof membrane.

    2 Roof and fittings shall be hosed down vigorously and this shall be repeated in such a way as
    to keep the roof wet for three successive days.

    3 Roof and fittings shall be deemed satisfactory for watertightness if no discernible leaks or
    damp patches show in the soffit.

    4 Roof covering shall be completed as soon as possible after testing.

    19.3.3 Disposal of Water Used for Testing

    1 The Contractor shall provide suitable means for disposal of water used for testing, such that

    l .
    no damage results to facilities, structures or property.

    .l.
    rw
    2 These means shall be subject to the approval of the Engineer and local authorities.

    3 Details shall be submitted to Engineer on request.

    4 ta
    The Contractor shall be responsible for damage caused by his filling, testing, flushing and
    qa
    wastewater disposal operations.
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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 02: Aggregates

    2 AGGREGATES ....................................................................................................... 2
    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope 2
    2.1.2 References 2
    2.1.3 Definitions 3
    2.1.4 Source Approval 4
    2.1.5 Sampling 4
    2.2 QUALITY AND TESTING ........................................................................................ 5
    2.3 STORAGE AT CONTRACTOR PLANT ................................................................... 5
    2.4 FINE AGGREGATE FOR CONCRETE AND MORTAR ........................................... 7
    2.5 COARSE AGGREGATE FOR CONCRETE............................................................. 8
    2.6 COMBINED AGGREGATE FOR CONCRETE......................................................... 8

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    2.7 WASHING AND PROCESSING .............................................................................. 9

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    2.8 LIGHTWEIGHT AGGREGATES.............................................................................. 9
    2.9 COARSE RECYCLED AGGREGATES ................................................................... 9

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    QCS 2014 Section 05: Concrete Page 2
    Part 02: Aggregates

    2 AGGREGATES

    2.1 GENERAL

    2.1.1 Scope

    1 This part covers the requirements of aggregates for use in structural concrete.

    2 Related Sections and Parts are as follows:

    This Section.....
    Part 3, .............. Cementitious Materials
    Part 4, .............. Water
    Part 6, .............. Property Requirements

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    Part 7, .............. Concrete Plants

    .l.
    Part 8, .............. Transportation and Planning of Concrete

    rw
    Part 15, ............ Hot weather Concreting
    Part 17, ............ Structural Precast Concrete
    Part 18, ............ Prestressed Concrete

    2.1.2 References ta
    qa
    ASTM C33 ..................Standard Specification for Concrete Aggregates
    ASTM C40 ..................Test Method for Organic Impurities in Fine Aggregates for Concrete
    as

    ASTM C88 ..................Test Method for Soundness of Aggregates by Use of Sodium Sulphate
    or Magnesium Sulphate
    se

    ASTM C123 ................Test Method for Lightweight Pieces in Aggregate


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    ASTM C127 ................Test Method for Specific Gravity and Absorption of Coarse Aggregate
    ASTM C128 ................Test Method for Specific Gravity and Absorption of Fine Aggregate
    ov

    ASTM C131 ................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 C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse
    it

    Aggregate
    et

    ASTM C142 ................Test Method for Clay Lumps and Friable Particles in Aggregates.
    m

    ASTM C535 ................Test Method for Resistance to Degradation of Large-Size Coarse


    Aggregate by Abrasion and Impact in the Los Angeles Machine
    ASTM C702 ................Standard Practice for Reducing Samples of Aggregate to Testing Size
    ASTM D75 ..................Standard Practice for Sampling Aggregates

    BRE Digest 330-2.......Alkali-Silica Reaction in Concrete Detailed Guidance for New


    Construction.

    BS 933-3 ....................Tests for geometrical properties of aggregates Determination of


    particle shape. Flakiness index
    BS 933-7 ....................Tests for geometrical properties of aggregates Determination of shell
    content. Percentage of shells in coarse aggregates
    BS 933-9 ....................Tests for geometrical properties of aggregates Assessment of fines.
    Methylene blue test
    QCS 2014 Section 05: Concrete Page 3
    Part 02: Aggregates

    BS 933-11 ..................Tests for geometrical properties of aggregates Classification test for


    the constituents of coarse recycled aggregate
    BS 1097-6 ..................Tests for mechanical and physical properties of aggregates
    Determination of particle density and water absorption
    BS 8500 part 2 ...........Concrete. Complementary British Standard to BS EN 206-1.
    Specification for constituent materials and concrete
    BS EN 12620 ..............Aggregates for concrete
    BS EN 1744-1 ............Tests for chemical properties of aggregates, Chemical analysis
    BS EN 1744-5 ............Tests for chemical properties of aggregates. Determination of acid
    soluble chloride salts
    BS EN 1367-2 ............Tests for thermal and weathering properties of aggregates.
    Magnesium sulphate test. BS EN 1367-4 Determination of drying
    shrinkage

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    BS EN 933 ..................Tests for geometrical properties of aggregates

    .l.
    BS EN 1097-2 ............Tests for mechanical and physical properties of aggregates. Methods

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    for the determination of resistance to fragmentation

    ta
    BS EN 1097-6 ............Tests for mechanical and physical properties of aggregates.
    Determination of particle density and water absorption
    qa
    BS EN13055-1 ...........Lightweight aggregates. Lightweight aggregates for concrete, mortar
    and grout.
    as

    BS PD 6682-1 ............Aggregates for concrete. Guidance on the use of BS EN 12620


    BS PD 6682-4 ............Aggregates Lightweight aggregates for concrete, mortar and grout.
    se

    Guidance on the use of BS EN 13055-1


    er

    EN 13139 ..................Aggregates for mortar


    ov

    EN 998-1 ...................Specification for mortar for masonry Rendering and plastering mortar
    EN 998-2 ...................Specification for mortar for Masonry mortar
    it o

    ISO 9001:2008 ...........Quality management systems -- Requirements


    et

    ISO 17025 ..................General requirements for the competence of testing and calibration
    m

    laboratories
    RILEM AAR1 ..............RILEM Recommended Test Method AAR-1 Detection of potential
    alkali-reactivity aggregates, Petrographic method
    RILEM AAR3 ..............RILEM Recommended Test Method AAR-3 Detection of potential
    alkali-reactivity - 38C test method for aggregate combinations using
    concrete prisms

    2.1.3 Definitions

    1 Aggregate: granular material used in construction and may be natural, manufactured or


    recycled.

    2 Natural aggregate: aggregate from mineral sources which has been subjected to nothing
    more than mechanical processing.
    QCS 2014 Section 05: Concrete Page 4
    Part 02: Aggregates

    3 Manufactured aggregate: aggregate of mineral origin resulting from an industrial process


    involving thermal or other modification.

    4 Recycled aggregate: aggregate resulting from the processing of inorganic material previously
    used in construction.

    5 Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding
    2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.

    2.1.4 Source Approval

    1 The Contractor shall use only those imported materials sourced from an Accredited Quarry
    Producer or Accredited Supplier and which have been approved by Qatar Standards or their
    representatives.

    l .
    2 The accredited aggregate suppliers shall provide the source name(s) for every shipment of

    .l.
    aggregates delivered to the concrete supplier.

    rw
    3 The source of material supply may be changed by the Contractor during the project, provided
    that the replacement materials shall be sourced from an Accredited Quarry Producer and the

    ta
    replacement materials are not significantly different in terms of physical and chemical
    properties, thus ensuring that the resultant concrete continues to comply fully with the
    qa
    specified requirements.
    as

    4 When considering whether an aggregates supplier and aggregates producer are suitable to
    be Accredited, preference will be given to organisations with a proper quality management
    se

    system, such as ISO 9001 or another quality management system approved by Qatar
    Standards.
    er

    5 When requested by the engineer, the aggregate supplier shall provide a geotechnical
    ov

    analysis on the rock samples before blasting and grinding to ensure the proper quality of
    materials.
    o

    6 The aggregates shall be properly stocked and labelled without intermingling at any storage
    it

    area.
    et

    7 When requested by the engineer, the aggregates supplier shall provide data for the past 6
    m

    months that shows the consistency of materials and conformity with this specification.

    8 The supplier shall verify the compliance of aggregates as per QCS by an independent
    qualified testing agency accredited to ISO 17025, and approved by Qatar Standards.

    2.1.5 Sampling

    1 The Contractor shall provide samples of both fine and course aggregate to the Engineer, in
    accordance with the requirements of relevant standards in QCS for sampling, sample
    reducing and testing of Aggregates, for testing at least two weeks before beginning deliveries
    to the Site.

    2 All samples shall be taken in the presence of the Engineer or an approved testing agency
    assigned by the Engineer.

    3 Aggregate sampling and testing shall be conducted by qualified staff.


    QCS 2014 Section 05: Concrete Page 5
    Part 02: Aggregates

    2.2 QUALITY AND TESTING

    1 Aggregates shall consist of tough, hard, durable and uncoated particles containing no
    harmful material in quantities sufficient to adversely affect the concrete or reinforcing steel,
    and shall contain no materials likely to cause staining or otherwise disfigure the concrete
    surface.

    2 Aggregates shall be obtained from a source approved by the Engineer.

    3 Aggregate shall meet the requirements given in Table 2.1. Additional tests detailed in BS EN
    12620 with BS PD 6682, EN 13139, EN 998-1, EN 998-2, or relevant ACI and ASTM
    standards and codes of practice may be required by the Engineer to satisfy certain
    requirements.

    4 Contractor shall provide all data as specified in QCS.

    l .
    .l.
    5 Sampling of the aggregates shall be carried out in accordance with the requirements of BS

    rw
    EN 12620, BS EN 933, or ASTM D75 and ASTM C702.

    6 Fine aggregates shall be natural sand or manufactured crushed rock sand. Crushed rock

    ta
    sand shall be the direct product of a manufacturing process, not the by-product of coarse
    qa
    aggregate production.

    7 Beach sand shall not be permitted for use in concrete mixes.


    as

    8 The use of clean Dune Sand, blended with coarser sand, may be permitted providing it can
    se

    be shown that the sand is free from contaminants. The use of local Dune sand shall be
    preapproved by the Ministry of Environment.
    er

    9 Samples of aggregates shall be taken in accordance with the requirements of Table 1.1- Part
    ov

    1.

    10 Frequency of routine testing shall meet the requirements as listed in Section 2. Frequency of
    o

    testing may be increased by the engineers request if testing results show inconsistency, and
    it

    frequency may be reduced if approved by the engineer if materials are highly consistent.
    et

    11 Mineralogical tests are to be carried out as instructed by the Engineer.


    m

    12 No aggregate deliveries shall be made to the Site until the Engineer has approved the
    samples as complying with this specification.

    2.3 STORAGE AT CONTRACTOR PLANT

    1 Aggregate shall be stored as follows:

    (a) each nominal size of coarse aggregate and fine aggregate shall be kept separated and
    clearly labelled at all times.
    (b) The height of stockpiles shall be controlled to prevent harmful segregation and
    breakage of the aggregate.
    (c) stockpiles shall be on hard and clean surfaces with not more than 5 % slope
    QCS 2014 Section 05: Concrete Page 6
    Part 02: Aggregates

    (d) contamination of the aggregates by the ground or other foreign matter shall be
    effectively prevented at all times
    (e) each heap of aggregate shall be capable of draining freely
    (f) stockpiles shall be protected from direct sunlight
    (g) unloading of aggregate shall be controlled to prevent harmful segregation and
    breakage.

    2 The Contractor shall maintain the stockpiles of coarse aggregate in separate gradings.

    3 At the construction site, the preparation, location and size of any stockpile shall be approved
    by the Engineer.
    Table 2.1
    Limits for Physical, Chemical and Mechanical Properties of Aggregates for Normal Concrete

    l .
    1

    .l.
    Test Methods Permissible Limits
    No. Requirement

    rw
    BS / EN ASTM Fines Coarse

    1. Grading 933-1 Standard Standard

    2. Natural: materials finer than 0.063 mm. 933-1 ta 3% max 2% max


    qa
    Crushed rock: materials finer than 7% max 2% max
    0.063mm.
    3. Fines quality
    as

    a) Structural concrete
    2
    Sand Equivalent (%) 933-8 60% min
    se

    b) Non-structural concrete
    Methylene blue adsorption 933-9 1.0 (g/kg)
    3
    er

    value (0/2mm) max


    4. Clay lumps and friable particles C142 2% max 2% max
    ov

    5. Lightweight pieces C123 0.5% max 0.5% max

    6. Organic impurities for fine aggregates C40 Colour NA


    o

    standard not
    it

    darker than
    4
    plate No. 3
    et

    7. Water absorption (saturated surface 1097-6 2.3% max 2.0% max


    dry)
    m

    8. Particle density for normal weight 1097-6 2.0 min 2.0 min
    concrete

    9. Shell Content: 933-7 3% max 3% max

    10. Flakiness index 933-3 35% max

    11. Acid-soluble chlorides: 1744-5

    a) Reinforced and mass concrete 0.06% max 0.03% max

    b) Prestressed concrete and steam


    5
    cured structural concrete 0.01% 0.01%
    QCS 2014 Section 05: Concrete Page 7
    Part 02: Aggregates

    1
    Test Methods Permissible Limits
    No. Requirement
    BS / EN ASTM Fines Coarse

    12. Acid-soluble sulphate 1744-1 0.4% max 0.3% max

    13. Soundness by magnesium sulphate (5 1367-2 15% max 15% max


    cycles)

    Resistance to fragmentation: Los


    14. Angeles abrasion 1097-2 30% max

    15. Drying shrinkage 1367-4 0.075% max

    .
    16. Potential reactivity: See Note 6 below

    l
    .l.
    rw
    Notes:
    1. Use of BS EN or relevant GSO standards.
    2. If the Sand Equivalent value is less than 60% and greater than or equal to 50%, the sand shall be

    ta
    considered non-harmful and is accepted provided that the Methylene Blue value is less than or equal to
    1.0 (g/kg).
    qa
    3. Not required when the fines content in the fine aggregate, or in the all-in aggregate, is 3% or less.
    4. Organic impurities: use of a fine aggregate failing in the test is not prohibited, provided that:
    a. The discoloration is due principally to the presence of small quantities of coal, lignite, or similar
    as

    discrete particles.
    b. When tested for the effect of organic impurities on strength of mortar, the relative strength at 7
    se

    days, calculated in accordance with ASTM C87, is not less than 95 %.


    5. If the chloride content is higher than 0.01% the following steps may be taken:
    er

    a- The aggregates may be washed by suitable water (Sec 5 Part 4) before mixing to lower the chloride
    content to the specified value (0.01%).
    ov

    b- If the washing process does not reduce the chloride content to the required value, then the Acid
    Soluble Chloride content in the concrete ingredients (the sum of the contributions from the
    constituent materials) shall be tested as mentioned in BS 8500-2. The allowable Acid Soluble
    o

    chloride content limit shall not exceed the values given in Section 5, Part 6, Para 6.5.3.
    6. The alkali-aggregate reactivity shall be assessed at source in accordance with BS 206-1 and BS 8500-
    it

    2. Certification shall be obtained from the aggregate source indicating absence of deleterious
    et

    expansion of concrete due to alkali aggregate reactivity.


    m

    2.4 FINE AGGREGATE FOR CONCRETE AND MORTAR

    1 Fine aggregate consist of natural clean sand, stone screenings or a combination and can be
    produced from natural disintegration of rock or gravel and/or by the crushing of rock or gravel
    or processing of manufactured aggregate or artificial, conforming to the requirements of
    physical and chemical properties complying with Table 2.1 and subject to the Engineer's
    acceptance.

    2 Crushed fine aggregates may be blended with local washed sand provided that the final
    aggregate complies with the requirements in Table 2.1.

    3 The gradation of fine aggregate for concrete and mortar shall be in accordance with the
    gradation designations in BS EN 12620 with BS PD 6682, EN 13139 , EN 998-1 , EN 998-2,
    or relevant ACI and ASTM standards and codes of practice and subject to the Engineers
    acceptance.
    QCS 2014 Section 05: Concrete Page 8
    Part 02: Aggregates

    4 Each batch of aggregate delivered to the Site shall be kept separate from previous batches,
    and shall be stored to allow for inspection and tests to be carried out.

    5 Local natural sand shall be mechanically washed to remove salts and other impurities in
    order to meet the specified requirements.

    6 The storage area for the clean washed sand shall be shaded from the direct rays of the sun
    and shall be screened for protection from dust. The area in the neighbourhood of
    stockpile/mixing plant shall be watered as necessary, to reduce the rising of dust.

    7 The usage of Dune sand shall be accepted as governed by the regulations of Qatar Ministry
    of Environment and shall be:

    (a) Not used for any reinforced concrete


    (b) Used only for blocks, block mortar, plasters, soil cement, shotcrete and insulation

    l .
    concrete.

    .l.
    rw
    2.5 COARSE AGGREGATE FOR CONCRETE

    1 The coarse aggregate is granular material and may be natural, manufactured, recycled or a

    ta
    combination. It shall be free from deleterious matter and conforming to the requirements of
    qa
    physical and chemical properties in Table 2.1 as a minimum requirements and subject to the
    Engineer's acceptance within BS EN 12620, BS PD 6682 or ASTM C33
    as

    2 For imported aggregate, Qatar Standards may publish more requirements and stringent limits
    than specified in Table 2.1.
    se

    3 For other types of concrete mixes and subject to Engineer's acceptance, coarse aggregate
    er

    shall comply with the relevant BS EN or relevant ACI and ASTM standards and codes. The
    nominal maximum size of coarse aggregate shall be not larger than: (a) 1/5 the narrowest
    ov

    dimension between sides of forms, nor (b) 1/3 the depth of slab, nor (c) 3/4 the minimum
    clear spacing between individual reinforcing bars or wires, bundles of bars, individual
    tendons, bundled tendons, or ducts.
    it o

    4 These limitations shall not apply if, in the judgment of the licensed design professional,
    et

    workability and methods of consolidation are such that concrete can be placed without
    m

    honeycombs or voids.

    5 As requested by the Engineer, the Contractor shall mechanically wash the aggregates to
    remove salts and other impurities in order to meet the requirements specified.

    2.6 COMBINED AGGREGATE FOR CONCRETE

    1 The material passing the 0.063mm sieve shall not exceed 3.0 % of the combined aggregate
    (by weight). The combined aggregate gradation used in the work shall be as specified,
    except when otherwise approved or directed by the Engineer.

    2 Changes in the approved gradation shall not be made during the progress of the works
    unless approved or directed by the Engineer.
    QCS 2014 Section 05: Concrete Page 9
    Part 02: Aggregates

    2.7 WASHING AND PROCESSING

    1 Where aggregates have been washed shortly before delivery to the Site, or if stockpiles have
    been sprayed to cool them, samples of the aggregate shall be taken frequently to determine
    the correct amount of water to add to the mix.

    2.8 LIGHTWEIGHT AGGREGATES

    1 Lightweight aggregates are those having particle densities not exceeding 2,000 kg/m3 or
    3
    loose bulk densities not exceeding 1200 kg/m .

    2 Lightweight aggregates include natural aggregate, aggregate manufactured from natural


    materials and/or a by product of industrial processes, and some recycled aggregate.

    .
    3 Lightweight aggregates shall be in accordance with BS EN13055-1 and BS PD 6682-4, or

    l
    .l.
    equivalent ASTM standards.

    rw
    2.9 COARSE RECYCLED AGGREGATES

    1
    ta
    Excavation Waste (EW), coarse recycled aggregates (RA), and coarse recycled concrete
    aggregates (RCA) shall meet with the requirements of Table 2.1, with the exception that
    qa
    water absorption shall not exceed;

    (a) 3% for structural concrete


    as

    (b) 4% for non-structural concrete.


    se

    2 For structural concrete EW and/or RCA may be used in designated concrete of maximum
    C30. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS
    er

    8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.
    ov

    3 For non-structural concrete, such as crash barriers and soakaways, EW and/or RCA may be
    used in designated concrete of maximum C40. Its proportion shall be not more than a mass
    o

    fraction of 50% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar
    it

    Standards to use a higher proportion.


    et

    4 For non-structural concrete RA may be used in designated concrete of maximum C25. Its
    m

    proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2
    sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.

    5 When the composition of coarse RCA and coarse RA is tested in accordance with BS EN
    933-11, the test result obtained for each type of particle shall not exceed the maximum value
    specified in Table 2.2.

    6 EW aggregate shall meet the same requirements for RCA, as given in Table 2.2.
    QCS 2014 Section 05: Concrete Page 10
    Part 02: Aggregates

    Table 2.2
    Requirements for coarse RCA and coarse RA, (mass fraction, %)

    1
    Requirement

    Maximum
    Type of
    foreign Maximum
    Aggregate Maximum Maximum
    Maximum Maximum material acid soluble
    masonry lightweight
    fines 2 Asphalt e.g. glass, sulphate
    content material
    plastic, (SO3)
    metals
    1, 3
    RCA 5.0 5.0 0.5 5.0 1.0 1.0

    .
    RA 100 3 1.0 10.0 1.0 -4

    l
    .l.
    rw
    1. Where the material to be used is obtained by crushing hardened concrete of known
    composition that has not been in use, e.g. surplus precast units or returned fresh concrete,
    and not contaminated during storage and processing, the only requirements are those for

    2.
    grading and maximum fines.
    Material with a density less than 1,000 kg/m3
    ta
    qa
    3. The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates
    blended with the listed constituents.
    4. The appropriate limit and test method needs to be determined on a case-by-case basis (see
    Note 6 to 4.3 of BS 8500-2).
    as

    3
    7 The floating material (FL) content, as per BS EN 933-11, shall not exceed 5.0 cm /kg.
    se

    8 RCA should be treated as highly reactive aggregate. The alkali contribution from RCA shall
    be determined as given in BS 8500-2.
    er
    ov

    9 For manufacturing of masonry concrete blocks, the usage of recycled aggregates is


    permitted up to 100% as given in Sec. 13 in accordance with ACI 555.
    it o
    et

    END OF PART
    m
    QCS 2014 Section 05: Concrete Page 1
    Part 20: Personnel Qualifications and Certification

    20 PERSONNEL QUALIFICATIONS AND CERTIFICATIONS ..................................... 2


    20.1 GENERAL ............................................................................................................... 2
    20.2 AUDITORS .............................................................................................................. 2
    20.3 READY MIXED CONCRETE COMPANIES ............................................................. 2
    20.3.1 Technical Department 2
    20.3.2 Production and Operation Department 4
    20.4 TESTING LABORATORIES .................................................................................... 5
    20.4.1 Concrete Laboratory Department 5
    20.5 CONTRACTORS ..................................................................................................... 6
    20.5.1 Concrete Construction Department 6
    20.6 CONSULTANTS ...................................................................................................... 7

    l .
    20.6.1 Site Supervision Department 7

    .l.
    20.6.2 Site Supervision / Design Office Department 7

    rw
    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 05: Concrete Page 2
    Part 20: Personnel Qualifications and Certification

    20 PERSONNEL QUALIFICATIONS AND CERTIFICATIONS

    20.1 GENERAL

    1 The qualification requirements given in this part are optional unless otherwise mentioned
    below. The purpose of the qualifications is to prepare the industry to cope with the required
    quality of construction. The requirements will become compulsory as and when stated by
    Qatar Standards.

    2 Qualifications shall be approved by Qatar Standards or their representatives.

    20.2 AUDITORS

    l .
    1 Qatar Standards auditors and their approved representatives shall be qualified for inspecting

    .l.
    concrete ready mix plants and testing laboratories.

    rw
    20.3 READY MIXED CONCRETE COMPANIES

    20.3.1 Technical Department


    ta
    qa
    1 Position: Technical Manager / QC Manager
    as

    Qualifications:
    (a) Concrete specification review and concrete mixture proportioning
    se

    (b) Concrete constituent materials, their characteristics, and effects on concrete properties
    er

    (c) Fresh and hardened concrete properties


    ov

    (d) Durability of concrete


    (e) Production and delivery of Ready Mixed Concrete
    o

    (f) Handling, placing and curing of concrete


    it

    (g) Specifying and evaluation of concrete strength


    et

    (h) Testing of concrete and its constituents


    m

    (i) Quality control procedures and statistical analysis


    (j) Hot weather concreting
    (k) Troubleshooting concrete problems

    2 Position: Site Supervisor

    Qualifications:
    (a) The supervisor shall be capable of satisfactorily reading, understanding and
    performing the below fresh concrete tests:

    BS EN 12350-1 ..........Testing fresh concrete - Sampling


    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    QCS 2014 Section 05: Concrete Page 3
    Part 20: Personnel Qualifications and Certification

    BS EN 12350-2 ..........Testing fresh concrete Slump test


    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

    3 Position: Lab Supervisor

    Qualifications:
    (a) The supervisor shall be capable of satisfactorily reading, understanding and
    performing the below fresh and hardened concrete tests:

    .
    BS EN 12350-1 .........Testing fresh concrete - Sampling

    l
    .l.
    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    BS EN 12350-2 .........Testing fresh concrete Slump test

    rw
    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)

    ta
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    qa
    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    as

    BS EN 12390-3 ..........Testing hardened concrete - Compressive strength of test specimens


    BS EN 932-1 .............Aggregates - Methods of sampling
    se

    BS EN 932-2 .............Aggregates Methods of reducing laboratory samples


    BS EN 933-1 .............Aggregates Determination of particle size distribution (and dust
    er

    content)
    ov

    BS EN 1097-6 ...........Aggregates Determination of particle density and water absorption


    BS EN 1097-3 ...........Aggregates Determination of loose bulk density and voids
    o

    ASTM C566 ............Method of determination of moisture content


    it
    et

    4 Position: Site Technician (compulsory if requested by the Engineer)


    m

    Qualifications:
    (a) The technician shall be capable of satisfactorily performing the below fresh concrete
    tests:

    BS EN 12350-1 .........Testing fresh concrete - Sampling


    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    BS EN 12350-2 .........Testing fresh concrete Slump test
    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    QCS 2014 Section 05: Concrete Page 4
    Part 20: Personnel Qualifications and Certification

    5 Position: Lab Technician (compulsory if requested by the Engineer)

    Qualifications:
    (a) The technician shall be capable of satisfactorily performing the below fresh and
    hardened concrete tests:

    BS EN 12350-1 .........Testing fresh concrete - Sampling


    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    BS EN 12350-2 .........Testing fresh concrete Slump test
    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests

    l .
    .l.
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens

    rw
    BS EN 932-1 .............Aggregates - Methods of sampling
    BS EN 932-2 .............Aggregates Methods of reducing laboratory samples

    ta
    BS EN 933-1 .............Aggregates Determination of particle size distribution (and dust
    qa
    content)
    BS EN 1097-6 ...........Aggregates Determination of particle density and water absorption
    BS EN 1097-3 ...........Aggregates Determination of loose bulk density and voids
    as

    ASTM C566 ............Method of determination of moisture content


    se
    er

    20.3.2 Production and Operation Department


    ov

    1 Position: Plant/Production/Operation Manager and/or Supervisor

    Qualifications:
    o

    (a) Properties of concrete and its constituents


    it
    et

    (b) Materials management


    m

    (c) Plant design, function and maintenance


    (d) Batching operations, procedures and dispatching
    (e) Materials management and inventory
    (f) Safety regulations and procedures

    2 Position: Plant Operator

    Qualifications:
    (a) Basic concrete properties and characteristics of its constituents
    (b) Scales, meters and batching sequence and control system
    (c) Central mixing and discharging
    (d) Tolerances, overweight/underweight controls
    QCS 2014 Section 05: Concrete Page 5
    Part 20: Personnel Qualifications and Certification

    (e) Troubleshooting scales, gates and other plant components


    (f) Safety procedures

    20.4 TESTING LABORATORIES

    20.4.1 Concrete Laboratory Department

    1 Position: Laboratory Manager / QC Manager

    Qualifications:
    (a) Concrete specification review and concrete mixture proportioning
    (b) Concrete constituent materials, their characteristics, and effects on concrete properties

    l .
    (c) Fresh and hardened concrete properties

    .l.
    (d) Durability of concrete

    rw
    (e) Production and delivery of Ready Mixed Concrete
    (f)
    (g)
    Handling, placing and curing of concrete
    Evaluation of concrete strength ta
    qa
    (h) Testing of concrete and its constituents
    as

    (i) Quality control procedures and statistical analysis


    (j) Hot weather concreting
    se

    (k) Troubleshooting concrete problems


    er
    ov

    2 Position: Supervisor

    Qualifications:
    o

    (a) The supervisor shall be capable of satisfactorily reading, understanding and


    it

    performing the below fresh and hardened concrete tests:


    et
    m

    BS EN 12350-1 .........Testing fresh concrete - Sampling


    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    BS EN 12350-2 .........Testing fresh concrete Slump test
    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens
    BS EN 932-1 .............Aggregates - Methods of sampling
    BS EN 932-2 .............Aggregates Methods of reducing laboratory samples
    BS EN 933-1 .............Aggregates Determination of particle size distribution (and dust
    content)
    QCS 2014 Section 05: Concrete Page 6
    Part 20: Personnel Qualifications and Certification

    BS EN 1097-6 ...........Aggregates Determination of particle density and water absorption


    BS EN 1097-3 ...........Aggregates Determination of loose bulk density and voids
    ASTM C566 ............Method of determination of moisture content

    3 Position: Technician (compulsory if requested by the Engineer)

    Qualifications:
    (a) The technician shall be capable of satisfactorily performing the below fresh and
    hardened concrete tests:

    BS EN 12350-1 .........Testing fresh concrete - Sampling


    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete

    .
    BS EN 12350-2 .........Testing fresh concrete Slump test

    l
    .l.
    BS EN 12350-6 .........Testing fresh concrete Density

    rw
    BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests
    ta
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    qa
    BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens
    BS EN 932-1 .............Aggregates - Methods of sampling
    as

    BS EN 932-2 .............Aggregates Methods of reducing laboratory samples


    BS EN 933-1 .............Aggregates Determination of particle size distribution (and dust
    se

    content)
    BS EN 1097-6 ...........Aggregates Determination of particle density and water absorption
    er

    BS EN 1097-3 ...........Aggregates Determination of loose bulk density and voids


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    ASTM C566 ............Method of determination of moisture content


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    20.5 CONTRACTORS
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    20.5.1 Concrete Construction Department


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    1 Position: Site Engineer

    Qualifications:
    (a) The site engineer shall be capable of satisfactorily reading, understanding and
    performing the below fresh concrete tests:
    BS EN 12350-1 .........Testing fresh concrete - Sampling
    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
    BS EN 12350-2 .........Testing fresh concrete Slump test
    BS EN 12350-6 .........Testing fresh concrete Density
    BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)
    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
    QCS 2014 Section 05: Concrete Page 7
    Part 20: Personnel Qualifications and Certification

    2 Position: QC Manager/ QC Engineer/ Material Engineer

    Qualifications:
    (a) Concrete specification review and concrete mixture proportioning
    (b) Concrete constituent materials, their characteristics, and effects on concrete properties
    (c) Fresh and hardened concrete properties
    (d) Durability of concrete
    (e) Production and delivery of Ready Mixed Concrete
    (f) Handling, placing and curing of concrete
    (g) Specifying and evaluating of concrete strength
    (h) Testing of concrete and its constituents

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    (i) Quality control procedures and statistical analysis

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    (j) Hot weather concreting
    (k) Troubleshooting concrete problems

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    20.6 CONSULTANTS

    20.6.1 Site Supervision Department


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    1 Position: Site Inspector/ Material Inspector


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    Qualifications:
    er

    (a) The site engineer shall be capable of satisfactorily reading, understanding and
    performing the below fresh concrete tests:
    ov

    BS EN 12350-1 .........Testing fresh concrete - Sampling


    o

    ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete


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    BS EN 12350-2 .........Testing fresh concrete Slump test


    et

    BS EN 12350-6 .........Testing fresh concrete Density


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    BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for


    strength tests
    ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete

    20.6.2 Site Supervision / Design Office Department

    1 Position: Material Engineer

    Qualifications:
    (a) Concrete specification review and concrete mixture proportioning
    (b) Concrete constituent materials, their characteristics, and effects on concrete properties
    (c) Fresh and hardened concrete properties
    (d) Durability of concrete
    QCS 2014 Section 05: Concrete Page 8
    Part 20: Personnel Qualifications and Certification

    (e) Production and delivery of Ready Mixed Concrete


    (f) Handling, placing and curing of concrete
    (g) Specifying and evaluating of concrete strength
    (h) Testing of concrete and its constituents
    (i) Quality control procedures and statistical analysis
    (j) Hot weather concreting
    (k) Troubleshooting concrete problems

    END OF PART

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    QCS 2014 Section 05: Concrete Page 1
    Part 03: Cementitious Materials

    3 CEMENTITIOUS MATERIALS................................................................................. 2
    3.1 GENERAL ............................................................................................................... 2
    3.1.1 Scope 2
    3.1.2 References 2
    3.1.3 Terms and Definitions: 3
    3.2 SOURCE APPROVAL ............................................................................................. 3
    3.3 SAMPLING .............................................................................................................. 3
    3.4 QUALITY AND TESTING ........................................................................................ 3
    3.5 DELIVERY, STORAGE AND HANDLING ................................................................ 4

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    QCS 2014 Section 05: Concrete Page 2
    Part 03: Cementitious Materials

    3 CEMENTITIOUS MATERIALS
    3.1 GENERAL

    3.1.1 Scope

    1 This Part covers the requirements for the testing and use of cement in structural concrete.

    2 Related Sections and Parts are as follows:


    Part 6 Property Requirements

    3.1.2 References

    1 The following standards are referred to in this Part:

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    ASTM C10 ..................Standard specification for natural cement

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    ASTM C91 ..................Specification for Masonry cement
    ASTM C114 ................Test methods for chemical analysis of Hydraulic Cement
    ASTM C115, ...............Test method for fineness of Portland cement by the Turbidimeter
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    ASTM C150 ................Standard specification for Portland cement
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    ASTM C183 ................Standard Practice for sampling and the amount of testing of Hydraulic
    cement
    as

    ASTM C188 ................Test method for density of Hydraulic cement


    ASTM C186 ................Test method for heat of hydration of Hydraulic cement
    se

    ASTM C204 ................Test method for fineness of Hydraulic cement by air permeability
    ASTM C348 ................Test method for flexural strength of Hydraulic cement mortar
    er

    ASTM C349 ................Test method for compressive strength of Hydraulic cement mortar
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    using portion of prism broken in flexure


    ASTM C430 ................Test method for fineness of Hydraulic cement by the 45mm (No.325)
    o

    ASTM C595 ................Standard specification for blended Hydraulic cement


    it

    ASTM C618 ................Standard Specification for Coal Fly Ash and Raw or Calcined Natural
    et

    Pozzolan for Use in Concrete


    ASTM C845 ................Specification for Expansive Hydraulic cement
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    ASTM C989 ..............Standard Specification for Slag Cement for Use in Concrete and
    Mortars
    ASTM C1157 ..............Standard performance specification for Hydraulic cement
    ASTM C1240 .............Standard Specification for Silica Fume Used in Cementitious Mixtures
    ASTM C1328 ..............Specification for plastic cement (Stucco)
    ASTM C1329 ..............Specification for Mortar cement

    BS 146 ........................Portland blast furnace cement


    BS 1370 ......................Low heat Portland cement
    BS 4027 ......................Sulphate-resisting Portland cement

    BS EN 196, .................Methods for testing cement


    QCS 2014 Section 05: Concrete Page 3
    Part 03: Cementitious Materials

    BS EN 197-1, .............Cement, Composition, specifications and conformity criteria for


    common cements.
    BS EN 197-4 .............Cement. Composition, specifications and conformity criteria for low
    early strength blastfurnace cements

    3.1.3 Terms and Definitions:

    1 Cementitious Materials: Portland cement in combination with one or more of the following:
    blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag,
    silica fume and Metakaolin; subject to compliance with requirements of this specification.

    2 PC: shall mean Portland cement or CEM I.

    3 FA or PFA: shall mean fly ash or pulverised fuel ash.

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    4 GGBS: shall mean ground granulated blast furnace slag.

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    3.2 SOURCE APPROVAL

    1 The Contractor shall submit to the Engineer for approval full details of the proposed source of

    ta
    cement. These sources of cement supply shall be regularly and thoroughly investigated to
    qa
    ensure that the quality of the material supply is satisfactory and that it does not deteriorate
    during the performance of the project.
    as

    2 The cement source shall not be changed without the Engineer's acceptance.

    The Contractor shall supply the Engineer with the manufacturers test certificates certifying
    se

    3
    that the cement is in compliance with the relevant standards.
    er

    4 For imported cement the manufacturers test certificates shall be provided with each
    ov

    consignment. The Contractor shall submit to the Engineer the date of manufacture and proof
    that the specifications have been complied with, certified by an independent agency in the
    country of origin.
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    5 Cement manufacturers shall label their packaging and delivery documents and shall provide,
    et

    where applicable, information on the packing/dispatch date, storage conditions and the
    storage period appropriate to maintaining the activity of any reducing agent and to keeping
    m

    the content of soluble chromium (VI) below the 2 ppm limit. The Engineer has the right to test
    the cement for presence of chromium at the contractors expense.

    3.3 SAMPLING

    1 The methods of obtaining samples of cement for testing shall be carried out as described in
    EN 196 or ASTM C183

    3.4 QUALITY AND TESTING

    1 The cementitious material shall fully comply with the relevant standard(s) from the following
    list:
    ASTM C150 ................Standard specification for Portland cement
    ASTM C595 ................Standard specification for blended Hydraulic cement
    QCS 2014 Section 05: Concrete Page 4
    Part 03: Cementitious Materials

    ASTM C618 ...............Standard specification for coal fly ash and raw natural pozzolan for use
    in concrete
    ASTM C989 ...............Standard specification for ground granulated blastfurnace slag for use
    in concrete and mortars
    ASTM C1157 ..............Standard performance specification for Hydraulic cement
    ASTM C1240 ..............Standard specification for silica fume used in cementitious mixtures

    BS 146 ........................Portland-blast furnace cement


    BS 1370 ......................Low heat Portland cement
    BS 4027 ......................Sulphate-resisting Portland cement
    BS EN 197-1, ............minimum grade 42.5
    BS EN 450 .................Fly ash for concrete.

    .
    BS EN 15167 .............Ground granulated blastfurnace slag for use in concrete, mortar and

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    grouts.

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    EN 12363 ..................Silica fume for concrete.
    Relevant GSO

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    The water-soluble chromium (VI) content shall not exceed 2ppm (0,0002%) by total dry
    weight of cementitious materials.
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    3.5 DELIVERY, STORAGE AND HANDLING
    as

    1 Cement shall be delivered to the Site in sealed and branded bags, or in the manufacturers
    containers, bearing the manufacturers name, cement type and date of manufacture, in
    se

    batches not exceeding 100 tons.


    er

    2 Cement shall be stored at the site in such a manner, as to prevent its deterioration, intrusion
    ov

    of moisture and foreign matter. It must be kept dry at all times. Immediately upon arrival at
    the Site the Contractor shall store the cement in
    o

    (a) bins or silos designed for the purpose. It shall be tight and provide for free movement
    it

    to discharge opening, or
    et

    (b) dry, weather tight and properly ventilated structures with floors raised a minimum of
    m

    450 mm above the ground with adequate provision to prevent absorption of moisture.

    3 All storage facilities shall be subject to the approval of the Engineer, and shall be such as to
    permit easy access for inspection and identification. Prolonged storage of cement at site is to
    be avoided.

    4 For bagged cement, each consignment of cement shall be kept separately, and the
    Contractor shall use the consignments in the order in which they are received.

    5 The Contractor shall keep records of the various consignments of cement in store, giving
    quantities received and used, and the sections of the work in which the cement has been
    used, on a daily basis and make a weekly return to the Engineer accordingly. Cement used in
    the Works shall be free flowing and free from lumps.

    6 In no case shall bagged cement be stored in stacks more than eight bags high.
    QCS 2014 Section 05: Concrete Page 5
    Part 03: Cementitious Materials

    7 A free passage of at least 1 m shall be left between the cement and the side walls of the
    structure.

    8 Different types of cement shall be kept in clearly marked separate storage facilities.

    9 Cement delivered to Site in drums or bags by the supplier or manufacturer shall be stored in
    the drums or bags until used in the Works.

    10 Any cement in drums or bags which have been opened shall be used immediately.

    11 Cement that has partially or fully caked in storage will not be permitted in work and shall be
    immediately removed from the storage area. Any bag or package or sample of cement which
    has been damaged, or rebagged or in any way has deteriorated shall be rejected either as an
    individual bag or package or as the whole consignment in which such bag, package or

    .
    sample is contained, as advised by the Engineer.

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    12 Where Site limitations preclude the storage of cement on Site, cement shall be stored at a

    rw
    central location and shall be delivered daily as required to specific job sites.

    13 The Contractor shall provide weighing machines which shall be kept permanently in each

    ta
    shed for checking the weight of the bags or barrels of cement. The weighing machines shall
    qa
    be calibrated by an independent agency. The Engineer shall have access at all times to the
    cement storage sheds.
    as

    14 During transport and storage the cement shall be fully protected from all weather elements.
    se

    15 Any consignment of cement not used within two months from the date of manufacture and
    cement which in the opinion of the Engineer is of doubtful quality shall not be used in the
    er

    Works until it has been retested and test result sheets showing that it complies in all respects
    with the specification and relevant standards have been delivered to the Engineer.
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    16 Cement stored for longer than 28 days shall be tested for loss on ignition" prior to use to
    check for deterioration, and any cement which fails the test shall not be used in the works.
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    END OF PART
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    QCS 2014 Section 05: Concrete Page 1
    Part 04: Water

    4 WATER ................................................................................................................... 2
    4.1 GENERAL ............................................................................................................... 2
    4.1.1 Scope 2
    4.1.2 References 2
    4.2 QUALITY OF WATER ............................................................................................. 3
    4.2.1 General 3
    4.2.2 pH of Water 3
    4.2.3 Permissible Temperatures 3
    4.2.4 Supply and Storage 3
    4.3 TESTING AND SAMPLING ..................................................................................... 3
    4.3.2 Health and Safety 5

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    QCS 2014 Section 05: Concrete Page 2
    Part 04: Water

    4 WATER

    4.1 GENERAL

    4.1.1 Scope

    1 This Part includes water used for concrete mixtures, washing of aggregates and equipment,
    wetting of surfaces or ponding during curing or for wetting formwork and washing
    reinforcement.

    2 Related Sections and Parts are as follows:

    This Section
    Part 2, .............. Aggregates

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    Part 6, .............. Property Requirements

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    Part 9, .............. Formwork

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    Part 10, ............ Curing
    Part 11, ............ Reinforcement

    4.1.2 References
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    1 The following standards are referred to in this Part:
    ASTM C109 ................test Method for Compressive Strength of Hydraulic Cement Mortars
    as

    (using 2-in or 50 mm Cube Specimens)


    se

    BS 1377 ......................Methods of test for soils for civil engineering purposes.


    BS 2690 ......................Methods of testing water used in industry
    er

    BS 6068 ......................Water quality


    ov

    BS EN ISO 9963-1 .....Determination of total and composite alkalinity


    o

    BS EN ISO 9963-2 .....Determination of carbonate alkalinity


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    et

    EN 196-1 ....................Determination of strength


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    EN 196-2 ....................Methods of testing cement - Part 2: Chemical analysis of cement


    EN 196-3 ....................Determination of setting time and soundness
    EN 1008 .....................Mixing water for concrete, Specification for sampling, testing and
    assessing the suitability of water, including water recovered from
    processes in the concrete industry, as mixing water for concrete
    SM 5220 B ................. Chemical Oxygen Demand (COD)
    SM 4500 ....................Standard Methods for the Examination of Water and Wastewater
    ISO 7890 ...............Water quality -- Determination of nitrate -- Part 1: 2,6-Dimethylphenol
    spectrometric method
    SM 3125B (ICP/MS) ...Metals by Inductively Coupled Plasma/Mass Spectrometry
    QCS 2014 Section 05: Concrete Page 3
    Part 04: Water

    4.2 QUALITY OF WATER

    4.2.1 General

    1 Potable water is suitable for use in concrete, while water of other origin such as underground
    water, natural surface water, recovered water, as well as municipal treated water or mixed
    water shall be tested to prove that its quality shall conform to water quality requirements as
    given below in 4.3.

    2 On site, where a permit is issued for Municipal Treated Effluent use for concrete, the effluent
    shall be treated by tertiary treatment stage: Reverse Osmosis (R.O.), and disinfection
    (Ultraviolet Radiation, or ozonation).

    3 The water shall be examined in accordance with the test procedures stated in Table 1, EN

    .
    1008. Water not conforming to one or more of the requirements in Table 1, EN 1008 may be

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    used only, if it can be shown to be suitable for use in concrete, in accordance with the
    physical tests of Table 1 below.

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    4 The site health and safety services and Treated Effluent Quality shall fulfil the requirements
    of 5

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    4.2.2 pH of Water

    1 The pH of water used in concrete works shall be as shown in Table 4.2.


    as

    4.2.3 Permissible Temperatures


    se

    1 Temperature of water for concrete shall not be less than 5 C and not more than 40 C
    er

    2 Water may be cooled to not less than 5 C by the gradual addition of chilled water or ice as
    ov

    follows:
    o

    (a) no ice particles shall be present in the mix


    it

    (b) alternatively, flaked ice may be used


    et

    (c) ice to be used shall be crushed and shall be a product of frozen water which
    m

    complies with the acceptance criteria of Tables 4.1 and 4.2 and 4.3.

    3 Every effort should be made to protect water pipes and tanks from the sun; e.g., burying,
    shading, insulation or painting white.

    4.2.4 Supply and Storage

    1 The Contractor shall make his own arrangements and obtain the approval of the Engineer for
    the supply of water.

    2 Storage of water should be such that contamination is prevented from occurring. Any
    measures taken to avoid contamination of the water shall be to the approval of the Engineer.

    4.3 TESTING AND SAMPLING

    1 Whenever required to do so by the Engineer, the Contractor shall take samples of the water
    being used, or which it is proposed to use, for mixing concrete and test them for quality.
    QCS 2014 Section 05: Concrete Page 4
    Part 04: Water

    2 Samples of water of not less than 5 l shall be taken, sealed and sent for testing at an
    approved independent laboratory, prior to the approval of any water source, and whenever
    the sources of water is changed periodically during the continuance of its use.

    3 Water of questionable quality should comply with the physical tests of Table 4.1 and chemical
    limitations listed in Table 4.2 & Table 4.3.

    4 No source of water shall be used until the required tests have demonstrated its suitability for
    concreting.

    5 The use of water from a municipal or government supply does not preclude the requirement
    for testing.

    Table 4.1

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    Acceptance Criteria and Physical Tests for Mixing Water

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    Test Method Limits

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    Compressive strength at 7 d, min % of control EN 196-1 90 %

    Setting time, max. deviation from control, (h:min) ta


    EN 196-3 from 1:00 early to 1:30 later
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    Table 4.2
    Chemical Limitations for Mixing Water
    se

    Maximum Limit,
    Parameter Test Method
    mg/l
    er

    (a) Chloride (as CI) BS 6068-1.37 (ISO


    ov

    9297)
    (a-1) for Prestressed concrete. 500
    o

    (a-2) for reinforced concrete. 1000


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    et

    (a-3) for concrete without reinforcement. 4500


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    2-
    (b) Sulphates (as SO4 ) EN 196-2 2000

    (c) Alkali BS 6068-2.51

    (c-1) Alkali carbonates and bicarbonates BS EN ISO 9963-1


    BS EN ISO 9963-2 500

    (c-2) Alkali equivalent sodium oxides EN 196-2 1500

    (d) Total dissolved ions, including BS 1377 : Part 3


    a, b and c above

    (d-1) for prestressed concrete 1000


    (d-2) reinforced concrete. 2000
    (d-3) for concrete without reinforcement. 5000

    (e) pH BS 6068-2.50 6.5 - 9.0


    QCS 2014 Section 05: Concrete Page 5
    Part 04: Water

    Table 4.3
    Maximum limit of Harmful Contaminants

    Parameter Test Method Maximum Limit, mg/l

    COD SM 5220 B 50

    SM 4500 P B, C, SM 4500
    Phosphate; expressed as PO4 - P 30
    PD by subtraction
    -
    Nitrate; expressed as NO3 -N ISO 7890-1 100

    2+

    .
    Lead; expressed as Pb SM 3125B (ICP/MS) 100

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    2+
    Zinc; expressed as Zn SM 3125B (ICP/MS) 100

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    SM: Standards Methods for the Examination of Water and Wastewater.

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    4.3.2 Health and Safety
    as

    1 On site, where a permit is issued for Municipal Treated Water use in construction works, the
    effluent should be treated by tertiary treatment stage including filtration and disinfectant
    se

    (Chlorine alone, or Ultraviolet Radiation, or ozonation). Furthermore, the following site health
    and safety services and the Treated Effluent Quality shall be fulfilled:
    er

    (a) Residual chlorine level shall be within the range of 0.5 1.0 mg/l. For water to be used
    ov

    for concrete, the disinfectant shall be Ultraviolet Radiation, or ozonation.


    (b) Coliform level shall fulfil one of the following:
    o

    (i) Fecal Coliform < 200 CFU/100 ml, in case there is no direct exposure on site
    it

    labour.
    et

    (ii) Total Coliform < 23 CFU/100 ml, in case there is direct exposure on site labour.
    m

    (c) The site shall be facilitated by health and safety guidelines signs, where it is indicated
    by Arabic, English, and any other languages where there are 5 workers or more on the
    site, that Water not for Human Consumption
    (d) The site shall be facilitated by health and safety equipment, as well as, personal health
    and safety protection equipment.
    (e) Labour shall follow health and safety guidelines and instructions and use their health
    and safety personal protection equibment.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 05: Admixtures

    5 ADMIXTURES ......................................................................................................... 2
    5.1 GENERAL ............................................................................................................... 2
    5.1.1 Scope 2
    5.1.2 References 2
    5.1.3 Definitions 2
    5.1.4 Submittals 2
    5.2 USE OF ADMIXTURES ........................................................................................... 3
    5.2.1 General 3
    5.2.2 Trials 3
    5.3 WATER PROOFING ADMIXTURES ....................................................................... 3
    5.3.1 General 3
    5.3.2 Water resisting admixtures 4

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    5.3.3 Permeability reducing admixture 4

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    5.3.4 Submittals 4

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    5.3.5 General 4
    5.3.6 Organic Corrosion Inhibitors 4
    5.3.7 Inorganic Corrosion Inhibitors 5
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    QCS 2014 Section 05: Concrete Page 2
    Part 05: Admixtures

    5 ADMIXTURES

    5.1 GENERAL

    5.1.1 Scope

    1 This Part includes materials added to the concrete materials during mixing.

    2 Related Sections and Parts are as follows:

    This Section
    Part 1 ............... General
    Part 6 ............... Property Requirements
    Part 7 ............... Concrete Plants

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    Part 16 ............. Miscellaneous

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    5.1.2 References

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    1 The following standards and other documents are referred to in this Part:

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    ACI 212.3R-10............Report on Chemical Admixtures for Concrete
    qa
    ACI 302 ......................Guide for Concrete Floor and Slab Construction
    ACI 305 ......................Hot Weather Concreting
    as

    ACI 308 ......................Standard Practice for Curing Concrete


    se

    ASTM C494, ...............Standard Specification for Chemical Admixtures for Concrete


    ASTM C1582, .............Standard Specification for Admixtures to Inhibit Chloride-Induced
    er

    Corrosion of Reinforcing Steel in Concrete


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    BS EN 934 ..................Admixtures for concrete, mortar and grout (Parts: 2, 6)


    BS EN 196, ................Methods of testing cement
    BS EN 14889 .............Fibres for concrete Polymer fibres. Definitions, specifications and
    o

    conformity
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    NSF ............................ Standard 61


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    5.1.3 Definitions

    1 Admixtures are materials added during the mixing process of concrete to modify the
    properties of the concrete mix in the fresh and/or hardened state.

    5.1.4 Submittals

    1 In addition to the specified general requirements for approval of materials, approval of


    admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of
    dosing arrangements and performance.
    QCS 2014 Section 05: Concrete Page 3
    Part 05: Admixtures

    5.2 USE OF ADMIXTURES

    5.2.1 General

    1 Admixtures are materials added to the concrete materials during the mixing process to
    modify its properties in the fresh and/or hardened state.

    2 Where approved and or directed by the Engineer, admixtures shall be used as a means of:

    (a) enhancing concrete durability


    (b) increasing workability of the concrete without increasing the water:cement ratio
    (c) controlling retardation and setting time.

    3 Admixtures shall comply with the following BS EN 934 2 requirements or the equivalent

    .
    ASTM C494:

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    (a) water reducing/plasicizing admixture

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    (b) high range water reducing/plasticizer admixture
    (c) set retarding admixtures

    4 ta
    The methods and the quantities of admixture used shall be in accordance with the
    qa
    manufacturers instruction and subject to the Engineers approval after evaluation in trial
    mixes and shall in no way limit the Contractors obligations under the Contract to produce
    as

    concrete with the specified strength, workability and durability.


    se

    5 The effects of accidental overdose of the admixture and measure to be taken if an overdose
    occurs shall be provided by the Contractor to the Engineer.
    er

    6 No admixtures containing chlorides shall be used. In particular, the use of acceleration


    ov

    admixtures containing calcium chloride shall not be used.

    7 The use of the admixtures shall be controlled; i.e., strict quality control to ensure correct
    o

    dosages as prescribed by the manufacturer and justified by trial mixes to be used. A


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    calibrated dispenser or flowmeter shall be used for the addition of the admixture.
    et

    5.2.2 Trials
    m

    1 In addition to the standard requirements for the approval of materials, approval of admixtures
    shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing
    arrangements and performance, when a proven history of performance cannot be provided to
    the satisfaction of the Engineer.

    5.3 WATER PROOFING ADMIXTURES

    5.3.1 General

    1 The admixture shall be suitable for use in the Gulf condition, and specially formulated for
    higher ambient temperature.
    QCS 2014 Section 05: Concrete Page 4
    Part 05: Admixtures

    2 The admixture shall be added as per manufacturers datasheet. Approved third party
    laboratory verification shall be conducted prior to use of material for the works. The
    manufacturers technical representative shall be present to ensure proper dosage of
    admixture during the trial mix.

    5.3.2 Water resisting admixtures

    1 Water resisting admixtures may be used with the permission of the Engineer and shall
    comply with the requirements of BS EN 934-2.

    2 The admixture is to be added as per the Manufacturers supplier data sheet at the time of
    mixing. An approved lab verification shall be made prior to use,

    5.3.3 Permeability reducing admixture

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    1 The admixture shall be a permeability reducing admixture for Non-Hydrostatic Conditions

    .l.
    (PRAN) and for hydrostatic conditions (PRAH) as indicated by ACI 212.3R-10, or crystalline

    rw
    waterproofing admixture.

    2 For PRAH, independent testing shall be performed according to NSF Standard 61 and

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    approval for use of waterproofing material on structures holding potable water shall be
    evidenced by NSF certification.
    qa
    5.3.4 Submittals
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    1 The Contractor shall submit manufacturers' specifications, installation instructions and other
    se

    data to show compliance with the requirements of this part of the specification and the
    Contract Documents.
    er

    2 The Contractor shall submit comprehensive test results for the water proofing admixture as
    ov

    per the tests in the specification, and evidence of their ability to meet all the requirements
    specified.
    o

    3 The Contractor shall submit a guarantee for the water proofing admixture. The guarantee
    it

    shall be worded to reflect the required performance of the material and shall be approved by
    et

    the Engineer.
    m

    4 CORROSION INHIBITING ADMIXTURES

    5.3.5 General

    1 Where reinforced concrete structures are exposed to aggressive environment such as


    underground and marine structures, the use of a corrosion inhibiting admixture shall be used.

    2 Corrosion Inhibiting Admixtures shall comply with ASTM C1582 Standard Specification for
    Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete.

    5.3.6 Organic Corrosion Inhibitors

    1 The admixture shall be based on either aqueous emulsion of amines and esters or amine
    carboxylates and shall be capable of forming a protective corrosion resistant film around the
    steel reinforcement.
    QCS 2014 Section 05: Concrete Page 5
    Part 05: Admixtures

    2 The corrosion inhibitor shall be capable of effecting protection to the steel where concrete
    has cracked and allows access to the elements responsible for corrosion.

    3 Organic corrosion inhibitors have a fixed dosage rate independent of chloride levels and shall
    be incorporated at the dosage rate recommended and tested by the Manufacturer.

    5.3.7 Inorganic Corrosion Inhibitors

    1 Inorganic corrosion inhibitors shall be based on calcium nitrites capable of oxidizing steel to a
    more stable form increasing its passivity in the presence of chlorides.

    2 Dosage of inorganic corrosion inhibitors ranges from 10 to 30L/m3 depending on the


    expected chloride levels as defined by ACI 212 Table 13.1.

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    END OF PART

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    QCS 2014 Section 05: Concrete Page 1
    Part 06: Property Requirements

    6 PROPERTY REQUIREMENTS ............................................................................... 2


    6.1 GENERAL ............................................................................................................... 2
    6.1.1 Scope 2
    6.1.2 References 2
    6.1.3 Definitions: 6
    6.1.4 Submittals 7
    6.2 EXPOSURE CLASSES ......................................................................................... 10
    6.2.1 General 10
    6.2.2 Reinforcement corrosion and sulphate classes 10
    6.3 FRESH CONCRETE ............................................................................................. 12
    6.3.1 General 12
    6.4 GRADES OF CONCRETE..................................................................................... 13

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    6.5 DURABILITY REQUIREMENTS ............................................................................ 13

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    6.5.1 General 13

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    6.5.2 Maximum acid soluble chloride content 14
    6.5.3 Type of cementitious material 14
    6.5.4
    6.5.5
    Resistance to alkali-silica reaction
    Recommendations to resist reinforcement corrosion ta 15
    15
    qa
    6.5.6 Recommendations to resist sulphate attack 16
    6.5.7 Durability-Related Properties 16
    as

    6.6 DESIGN OF CONCRETE MIXES .......................................................................... 17


    6.6.1 Concrete 18
    se

    6.7 TRIAL MIXES ........................................................................................................ 25


    er

    6.8 QUALITY AND TESTING ...................................................................................... 27


    6.8.1 General 27
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    6.8.2 Tests for Concrete 27


    6.8.3 Hardened Tests for Fiber-Reinforced Concrete 29
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    6.8.4 Quality Control charts 29


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    6.9 WORKS TEST CUBES ......................................................................................... 30


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    6.10 REJECTION OF CONCRETE MIXES ................................................................... 30


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    6.10.1 Rejection of Concrete Mixes: 30


    6.10.2 Unsatisfactory Concrete Works 31
    QCS 2014 Section 05: Concrete Page 2
    Part 06: Property Requirements

    6 PROPERTY REQUIREMENTS

    6.1 GENERAL

    6.1.1 Scope

    1 This Part includes Grades 15 MPa and above of concrete to be used in the civil works, with
    the requirements for workability, permeability, and drying shrinkage.

    2 Related Sections and Parts are as follows:


    This Section
    Part 2, ........... Aggregates
    Part 3, ........... Cementitious Materials

    .
    Part 4, ............ Water

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    .l.
    Part 5, ........... Admixtures

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    Part 7, ............ Concrete Plants
    Part 8, ........... Transportation and Placing of Concrete
    Part 9, .............. Formwork

    ta
    Part 13, ............ Inspection and Testing of Hardened Concrete
    qa
    6.1.2 References

    1 The following standards are referred to in this Part. The designer along with contractor are
    as

    responsible to use the latest update standard as published by the organization:


    se

    ACI 207.1R .................Guide to Mass Concrete


    er

    ACI 207.2R .................Report on Thermal and Volume Change Effects on Cracking of Mass
    Concrete
    ov

    ACI 207.5R .................Roller - Compacted mass concrete


    ACI 213, .....................Guide for Structural Lightweight-Aggregate Concrete
    o

    ACI 214, .....................Evaluation of Strength Test Results of Concrete


    it

    ACI 221, .....................Guide for Use of Normal Weight and Heavyweight Aggregates in
    et

    Concrete
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    ACI 237R 07 ..............Self Consolidating Concrete


    ACI 301, .....................Specifications for Structural Concrete
    ACI 304, .....................Guide for Measuring, Mixing, Transporting, and Placing Concrete
    ACI 304.2, ..................Placing Concrete by Pumping Methods
    ACI 318, .....................Metric Building Code Requirements for Structural Concrete &
    Commentary
    ACI 506, ....................Guide to Shotcrete
    ACI 506.1, ..................Guide to Fiber-Reinforced Shotcrete
    ACI 506.2, ..................Specification for Shotcrete
    ACI 555, .....................Removal and Reuse of Hardened Concrete

    ASTM A 820, ..............Specification for Steel Fibers for Fiber-Reinforced Concrete


    ASTM C 31, ................Practice for making and curing concrete test specimens in the field
    ASTM C 33, ...............Specification for Concrete Aggregates
    QCS 2014 Section 05: Concrete Page 3
    Part 06: Property Requirements

    ASTM C 39, ................Test Method for Compressive Strength of Cylindrical Concrete


    Specimens
    ASTM C 42, ................Test Method for Obtaining and Testing Drilled Cores and Sawed
    Beams of Concrete
    ASTM C 94, ................Specification for Ready-Mixed Concrete
    ASTM C192, ...............Practice for Making and Curing Concrete Test Specimens in the
    Laboratory
    ASTM E 119, ..............Test Methods for Fire Tests of Building Construction and Materials
    ASTM C 138, ..............Test Method for Density (Unit Weight), Yield, and Air Content
    (Gravimetric) of Concrete
    ASTM C 150, .............Specification for Portland Cement
    ASTM C 172, ..............Practice for Sampling Freshly Mixed Concrete
    ASTM C 173, ..............Test Method for Air Content of Freshly Mixed Concrete by the

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    Volumetric Method

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    ASTM C 231 ...............Test Method for Air Content of Freshly Mixed Concrete by the

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    Pressure Method
    ASTM C 232, .............Test Methods for Bleeding of Concrete

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    ASTM C 311, .............Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans
    for Use in Portland-Cement Concrete
    qa
    ASTM C 387, ..............Specification for Packaged, Dry, Combined Materials for Mortar and
    Concrete
    as

    ASTM C 597, ..............Test Method for Pulse Velocity through Concrete


    ASTM C 617, .............Practice for Capping Cylindrical Concrete Specimens
    se

    ASTM C 618, .............Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan
    for Use in Concrete
    er

    ASTM C 637, ..............Specification for Aggregates for Radiation-Shielding Concrete


    ov

    ASTM C 638, .............Descriptive Nonmenclature of Constituents of Aggregates for


    Radiation-Shielding Concrete
    o

    ASTM C 803, .............Test Method for Penetration Resistance of Hardened Concrete


    it

    ASTM C 805, .............Test Method for Rebound Number of Hardened Concrete


    et

    ASTM C 856, .............Practice for Petrographic Examination of Hardened Concrete


    m

    ASTM C 900, .............Test Method for Pullout Strength of Hardened Concrete


    ASTM C 989, ..............Standard Specification for Slag Cement for Use in Concrete and
    Mortars
    ASTM C 1018, ............Test Method for Flexural Toughness and First-Crack Strength of Fiber-
    Reinforced Concrete
    ASTM C 1116, ...........Specification for Fiber-Reinforced Concrete
    ASTM C 1140, ............Practice for Preparing and Testing Specimens from Shotcrete Test
    Panels
    ASTM C 1152 .............Standard Test Method for Acid-Soluble Chloride in Morter and
    Concrete.
    ASTM C 1218 .............Standard Test Method for Water-Soluble Chloride in Morter and
    Concrete.
    ASTM C 1231, ............Practice for Use of Unbonded Caps in Determination of Compressive
    Strength of Hardened Concrete Cylinders
    QCS 2014 Section 05: Concrete Page 4
    Part 06: Property Requirements

    ASTM C 1240, ............Specification for Silica Fume Used in Cementitious Mixtures


    ASTM C 1385, ............Practice for Sampling Materials for Shotcrete
    ASTM C 1399, ............Test Method for Obtaining Average Residual-Strength of Fiber-
    Reinforced Concrete
    ASTM C 1480, ............Specification for Packaged, Pre-Blended, Dry, Combined Materials for
    Use in Wet or Dry Shotcrete Application
    ASTM C 1550, ............Test Method for Flexural Toughness of Fiber Reinforced Concrete
    (Using Centrally Loaded Round Panel)
    ASTM C 1604, ............Test Method for Obtaining and Testing Drilled Cores of Shotcrete
    ASTM C 1609, ............Test Method for Flexural Performance of Fiber-Reinforced Concrete
    (Using Beam With Third-Point Loading)
    ASTM C 1611, ............Test Method for Slump Flow of Self-Compacting Concrete
    ASTM C 1666, ............Specification for Alkali Resistant (AR) Glass Fiber for GFRC and

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    Fiber-Reinforced Concrete and Cement

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    ASTM D 5759, ............Guide for Characterization of Coal Fly Ash and Clean Coal

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    Combustion Fly Ash for Potential Uses
    ASTM D 6942, ............Test Method for Stability of Cellulose Fibers in Alkaline Environments

    ta
    qa
    BRE digest 433, .........Recycled Aggregates

    BS 4027, ....................Specification for Sulphate-Resisting Portland Cement


    as

    BS 6073-2:2008, ........Precast concrete masonry units. Guide for specifying precast concrete
    se

    masonry units
    BS 8500, ....................Concrete, Complementary British Standard to BS EN 206-1.
    er

    BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of


    steel reinforcement for concrete
    ov

    BS EN 206-1, ............Concrete. Specification, Performance, Production And Conformity


    BS EN 450,.................Fly Ash for Concrete. Definition, Specifications And Conformity Criteria
    o

    BS EN 771-3, .............Specification for masonry units. Aggregate concrete masonry units


    it

    (dense and light-weight aggregates


    et

    BS EN 772-2, ............. Methods of test for masonry units. Determination of percentage area
    m

    of voids in masonry units (by paper indentation)


    BS EN 12350,.............Testing Fresh Concrete
    BS EN 12350-1, .........Testing fresh concrete - Part 1: Sampling
    BS EN 12350-2, .........Testing fresh concrete - Part 2: Slump test
    BS EN 12350-3, .........Testing fresh concrete - Part 3: Vebe test
    BS EN 12350-4, .........Testing fresh concrete - Part 4: Degree of compactability
    BS EN 12350-5, .........Testing fresh concrete - Part 5: Flow table test
    BS EN 12350-6, .........Testing fresh concrete - Part 6: Density
    BS EN 12350-7, .........Testing fresh concrete - Part 7: Air content - Pressure methods
    BS EN 12390,.............Testing Hardened Concrete
    BS EN 12390-1, .........Testing hardened concrete - Part 1: Shape, dimensions and other
    requirements for specimens and moulds
    BS EN 12390-2, .........Testing hardened concrete - Part 2: Making and curing specimens for
    strength tests
    QCS 2014 Section 05: Concrete Page 5
    Part 06: Property Requirements

    BS EN 12390-3, .........Testing hardened concrete - Part 3: Compressive strength of test


    specimens
    BS EN 12390-4, .........Testing hardened concrete - Part 4: Compressive strength -
    Specification for testing machines
    BS EN 12390-5, .........Testing hardened concrete - Part 5: Flexural strength of test
    specimens
    BS EN 12390-6, .........Testing hardened concrete - Part 6: Tensile splitting strength of test
    specimens
    BS EN 12390-7, .........Testing hardened concrete - Part 7: Density of hardened concrete
    BS EN 12390-8, .........Testing hardened concrete - Part 8: Depth of penetration of water
    under pressure
    BS EN 12620,.............Aggregate For Concrete
    BS EN 15167 .............Ground Granulated Blast Furnace Slag For Use In Concrete, Mortar

    l .
    And Grout. Conformity Evaluation

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    BS EN 1744, ..............Tests For Chemical Properties Of Aggregates

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    BS EN 1992-3:2006 ...Eurocode 2. Design of concrete structures. Liquid retaining and
    containing structures

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    BS EN 1992-3:2006 ...UK National Annex to Eurocode 2. Design of concrete structures.
    Liquid retaining and containment structures
    qa
    BS PD 6682-1, ...........Aggregates for Concrete. Guidance on the Use of BS EN 12620
    as

    Concrete Society Report No. 31, Permeability testing of site concrete


    se
    er

    EN 1011, .................... Welding. Recommendation for welding of metallic materials


    EN 1992-1-1, ..............Eurocode 2: Design of concrete structures. General rules and rules for
    ov

    buildings
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    GSO ISO 1920-1 ........Testing of concrete Part 1: Sampling of fresh concrete


    it

    GSO ISO 1920-2 ........Testing of concrete part 2: properties of fresh concrete


    et

    GSO ISO 1920-3 ........Testing of concrete part 3: Making and curing test specimens.
    m

    GSO ISO 1920-4 .......Testing of concrete part 4: strength of hardened concrete.


    GSO ISO 1920-5 .......Testing of concrete part 5: properties hardened concrete other than
    strength.
    GSO ISO 1920-6 ........Testing of concrete part 6: sampling, preparing and testing of
    concrete core .
    GSO ISO 1920-7 .......Testing of concrete part 7: Non destructive test on hardened
    concrete.

    ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of


    concrete for samples prepared in the field or in the laboratory
    ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete
    cylinders in compression
    ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of
    elasticity in compression
    QCS 2014 Section 05: Concrete Page 6
    Part 06: Property Requirements

    CSTR11......................Concrete core testing The concrete Society


    RILEM CPC 11.3 .......Absorption of water by immersion under vacuum
    The Concrete Society CS163. Guide to the design of concrete structures in the Arabian
    Peninsula.
    The European Guidelines for Self-Compacting Concrete Specification, Production and Use

    6.1.3 Definitions:

    1 Exposure conditions will apply as follows:

    (a) Class X0: No risk of corrosion or attack. Non saline conditions. Blinding concrete, non-
    reinforced concrete or slab on ground.
    (b) Class X1: Mild exposure Non saline conditions (dry or wet, rarely dry) External

    .
    concrete at least 3m above ground level, internal concrete in dry conditions, concrete

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    permanently submerged in non-saline water or non-aggressive groundwater.
    (c) Class X2: Moderate exposure Non saline conditions (Cyclic wet and dry). External

    rw
    reinforced concrete less than 3m above ground level, water-retaining structures
    exposed to fluctuating water levels.
    (d)
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    Class X3: Aggressive exposure Permanently submerged or wet (rarely dry) Concrete
    in contact with groundwater including capillary rise zone, concrete containing or
    qa
    permanently exposed to saline water.
    (e) Class X4: Severe exposure Moderate humidity External concrete within 1km from
    as

    the sea or in contact with high saline water table or sabkhas. Concrete not affected by
    condensation, irrigation or leakage, which are more than 3m above ground level.
    se

    (f) Class X5: Extreme exposure Cyclic wet and dry, external concrete within 1km from
    the sea or in contact with high saline groundwater or sabkhas. Concrete affected by
    condensation, irrigation or leakage, which are less than 3m above ground level or
    er

    within capillary zone. Concrete surfaces exposed to sea water splash or in sea water
    tidal zone.
    ov

    (g) Sulphate exposure classes S1 to S4: the exposure classes are related to sulphate
    attack in relation to sulphate and pH of the ground water.
    o

    2 Concrete is a mixture (mix) of cementitious materials, coarse and fine aggregate, and water,
    it

    with or without admixtures, which develops its properties by cement hydration.


    et

    3 "Cementitious Materials": Portland cement in combination with one or more of the following:
    m

    blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag
    and silica fume; subject to compliance with requirements of this specification.

    4 Water/Cementitious Ratio shall mean the ratio between the total weight of water in the
    concrete (less the water absorbed by the aggregate) and the weight of cementitious
    materials, expressed as a decimal fraction.

    5 Admixtures shall mean a material other than water, aggregate, cementitious materials or
    fiber reinforcement, used as an ingredient of concrete or mortar. Admixtures are added
    during the mixing process of concrete to modify the properties of the concrete mix in the
    fresh and/or hardened state.

    6 Hot Weather shall mean any combination of the following conditions that tends to impair the
    quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and
    rate of cement hydration, or otherwise causing detrimental results such as: a. High ambient
    temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43
    deg C on a falling thermometer), b. High concrete temperature, c. Low relative humidity, d.
    2
    High wind speed and e. whenever the rate of evaporation exceeds 0.75 kg/m /h
    QCS 2014 Section 05: Concrete Page 7
    Part 06: Property Requirements

    7 Mass concrete is defined as any volume of concrete with dimensions large enough to
    require that measures be taken to cope with generation of heat form hydration of the cement
    and attendant volume change to minimize cracking. Reinforced Massive concrete structures
    include pile caps, transfer plates, and structural members where the least dimension
    exceeds 1.5 meters.

    8 Coarse Aggregate shall be considered as that size passing a 20mm sieve (or larger sieve
    size) and predominately retained on a 4mm sieve.

    9 Fine Aggregate shall be considered as that size predominately passing a 4mm sieve and
    predominately retained on a 0.063mm size.

    10 PC shall mean Portland cement or CEM I.

    11 FA shall mean pulverised fuel ash or fly ash.

    .
    12 GGBS shall mean ground granulated blastfurnace slag.

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    13 SF shall mean silica fume. Other names are condensed silica fume and microsilica

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    14 Gap-graded aggregate shall mean graded aggregate without one or more of the
    intermediate sizes.

    15 ta
    Single-size aggregate shall mean aggregates containing a major proportion of particles of
    qa
    one sieve size.

    16 Target Mean Strength shall mean the specified characteristic strength plus the margin.
    as

    17 Margin shall mean the difference between the specified characteristic strength and the
    se

    target mean strength.

    Acceptable or Accepted shall mean acceptable or accepted by the Engineer.


    er

    18

    Approval or Approved shall mean approval from the Engineer.


    ov

    19

    20 All-in aggregate shall mean the materials composed of a mixture of coarse and fine
    o

    aggregates.
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    21 Self-Compacting Concrete (SCC): concrete that is able to flow and consolidate under its own
    et

    weight, completely fill the formwork even in the presence of dense reinforcement, whilst
    m

    maintaining homogeneity and without the need for any additional compaction.

    6.1.4 Submittals

    1 The Contractor shall submit details of mix designs to the Engineer for approval.

    2 Material Safety Data Sheet MSDS or equivalent for all products. test results and other
    information as required to prove compliance with the specification shall be submitted to the
    Engineer for approval according to the relevant sections of QCS on at least the following
    products

    3 Cement:

    (a) Recent independent test results acceptable to the Engineer confirming compliance
    with the specified requirements and referenced standards.
    (b) Manufacturer's certificates shall also be supplied for each batch of production of
    cement or on a weekly basis, whichever is more frequent, certifying compliance with
    the BS EN 197 or other equivalent standard.
    QCS 2014 Section 05: Concrete Page 8
    Part 06: Property Requirements

    (c) The early compressive strength of each consignment of cement shall conform to the
    requirements of QCS part 3 at the independent site laboratory. Deviation of more than
    10% from either the previous consignment value or the rolling average shall be
    immediately reported to the Engineer. Testing at an independent laboratory shall be as
    instructed by the Engineer.

    4 GGBS:

    (a) Recent independent test results acceptable to the Engineer confirming compliance
    with the specified requirements and referenced standards.
    (b) Manufacturer's certificates with all information necessary to verify compliance shall
    also be supplied for each consignment of GGBS or on weekly basis, whichever is
    more frequent.
    (c) The early compressive strength of each consignment of GGBS shall be determined in
    accordance with BS EN 197 and BS EN 15167 or ASTM C989 at the independent site
    laboratory based on a blend of 50/50 % GGBS and CEM 1. Deviation of more than 5%

    l .
    in strength from either the previous consignment value or the rolling average shall be

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    immediately reported to the Engineer. Testing at an independent laboratory shall be in
    accordance with per BS EN 197 and BS EN 15167 standards, and approved by the

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    Engineer.

    5 FA:

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    Recent independent test results acceptable to the Engineer confirming compliance
    qa
    with specified requirements of BS EN 450 or ASTM C618.
    (b) Manufacturer's certificates with all information necessary to verify compliance with
    internationally recognized standards shall also be supplied with each consignment of
    as

    FA.
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    (c) The materials shall comply with QCS part 3. Deviation of the strength factor by more
    than 5% from either the previous consignment value or the rolling average shall be
    immediately reported to the Engineer and the Technical Manager of the premix
    er

    company.
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    6 Silica fume:

    (a) Recent independent test results acceptable to the Engineer confirming compliance
    o

    with specified requirements and referenced standards.


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    (b) Manufacturer's certificates with all information necessary to verify compliance with
    et

    internationally recognized standards shall also be supplied with each consignment of


    silica fume.
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    (c) 7 day pozzolanic activity test in accordance with BS EN 13263-1 or ASTM C 1240 on
    each consignment of silica fume at the Independent site laboratory. Deviation of the
    activity index by more than 5% from either the previous consignment value or the
    rolling average shall be immediately reported to the Engineer and the Technical
    Manager of the premix company.

    7 Aggregates:

    (a) Recent independent test results acceptable to the Engineer confirming compliance
    with the specified requirements and referenced standards.
    (b) Full details of the proposed sources of aggregates.

    8 Water: Recent independent test results acceptable to the Engineer confirming compliance
    with the specified requirements and referenced standards.
    QCS 2014 Section 05: Concrete Page 9
    Part 06: Property Requirements

    9 Admixtures: Manufacturers technical specifications and recommendations. Recent trial


    results acceptable to the Engineer illustrating the efficiency of the product for its particular
    application. Tests on specific gravity and solids content shall be conducted at the
    Independent site laboratory on each consignment.

    10 Mix Designs: Submit concrete mix designs for each type and strength of concrete required at
    least thirty (30) days before placing concrete.

    11 New mix designs, with historic data less than 6 months, shall be verified by an approved
    independent testing laboratory in accordance with requirements of QCS Part 05 and shall be
    coordinated with design requirements and Contract Documents.

    12 Submit complete mix design data for each separate mix to be used on the Project in a single
    submittal with at least the following information:

    (a) Type of cement*.

    .
    (b) Portland cement content*.

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    (c) Cementitious content* (GGBS, FA, natural pozzolan, rice husk ash and/or silica fume).

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    (d) Max. aggregate size*.
    (e) Combined grading curve for coarse aggregate
    (f) Quantities of all individual materials*
    ta
    qa
    (g) Type of admixture(s)*
    (h) Target slump/slump flow (at discharge)* as per BS EN 12350-2
    as

    (i) Initial and final concrete setting time for each mix design as per ASTM C403 or
    equivalent BS EN standards, if specified
    se

    (j) Fresh density of concrete as per BS EN 12350-6


    (k) Air content as per BS EN 12350-7
    er

    (l) Target temperature*


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    (m) Bleeding, if specified


    (n) Chloride and sulphate (SO3) contents
    o

    (o) Details of calculated water/cementitious material (w/c) ratio*


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    et

    (p) Compressive strength grade*


    (q) Hardened density
    m

    (r) Water absorption (%) and water penetration (mm), if specified


    (s) Rapid chloride permeability - Coulomb value, if specified
    2
    (t) Chloride migration coefficient (m /sec), if specified

    *Include on delivery ticket as a minimum

    13 Data shall be from the same production facility that will be used for the Project.

    14 Mix Design data shall include but not be limited to the following:

    (a) Locations on the Project where each mix design is to be used corresponding to
    Structural General Notes on the Drawings.
    3
    (b) Proportions: Concrete constituent materials shall be proportioned to yield 1 m
    (c) Submit strength test records, mix design materials, conditions, and proportions for
    concrete used for record of tests, standard deviation calculation, and determination of
    required average compressive strength, if required by the Engineer.
    QCS 2014 Section 05: Concrete Page 10
    Part 06: Property Requirements

    (d) If early concrete strength is required, contractor shall submit trial mixture results as
    required.
    (e) Test records to support proposed mixtures shall be no more than 12 months old and
    use current cement and aggregate sources. Test records to establish standard
    deviation may be older if necessary to have the required number of samples.
    (f) Manufacturer's product data for each type of admixture.
    (g) Manufacturers certifications that all admixtures used are compatible with each other.
    (h) All information indicating compliance with Contract Documents including method of
    placement and method of curing.

    15 Mass Concrete:

    (a) Submit mix design for mass concrete elements in conformance with requirements of
    ACI 301 Section 8. The concrete mix design shall not be designed with a high early
    strength unless otherwise demonstrated by the Contractor for capability of maintaining

    l .
    proper temperature and approved by the Engineer.

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    (b) Submit proposed methods of temperature control, including cementitious material

    rw
    content control in mix design to reduce heat-generating potential of concrete,
    precooling of ingredients to lower concrete temperature as placed, and methods to
    protect mass concrete elements from excessive temperature differentials.
    (c)
    ta
    Submit analysis of anticipated thermal development within mass concrete elements
    qa
    with the proposed mix design for these elements. Results of the analysis, using
    methods in ACI 207.1R and ACI 207.2R such as the Schmidt model and site specific
    data, shall address the maximum differential temperature and the maximum
    temperature during curing
    as

    (d) Submit proposed number and locations of temperature monitoring devices to record
    se

    temperature development between the interior and the exterior of mass concrete
    elements.
    er

    6.2 EXPOSURE CLASSES


    ov

    6.2.1 General

    1 The exposure classes are related to the environmental conditions surrounding the concrete
    o

    in service.
    it
    et

    2 The concrete may be subject to more than one of the classes described below, and the
    environmental conditions to which it is subjected need to be expressed as a combination of
    m

    exposure classes.

    3 Where two or more aggressive characteristics lead to the same class, the exposure shall be
    classified into the next higher class; unless a special study for this specific case proves that it
    is not necessary.

    4 For a given structure, different concrete elements may be subject to different environmental
    classes.

    6.2.2 Reinforcement corrosion and sulphate classes

    1 The classification system described below is based on the approach in BS EN 206-1, BS


    8500-1, and the Concrete Society CS 163.

    2 The exposure classes related to reinforcement corrosion are associated with carbonation and
    chlorides as per Table 6.1.
    QCS 2014 Section 05: Concrete Page 11
    Part 06: Property Requirements

    3 The exposure classes related to sulphate attack are given in Table 6.2 in relation to sulphate
    and pH of the ground water.

    4 The sulphate content as S04 mg/l shall be determined as per BS EN 196-2.

    5 The pH shall be determined as per ISO 4316.

    Table 6.1.
    Exposure classes for reinforcement corrosion

    Exposure Class Class description

    X0 No risk of corrosion or attack. Non saline conditions. Blinding concrete,


    non-reinforced concrete or slab on ground
    X1 Mild exposure Non saline conditions (dry or wet, rarely dry). External

    .
    concrete at least 3m above ground level, internal concrete in dry

    l
    .l.
    conditions, concrete permanently submerged in non-saline water or non-
    aggressive groundwater (Class S1).

    rw
    X2 Moderate exposure Non saline conditions (cyclic wet and dry). External
    reinforced concrete less than 3m above ground level, water-retaining
    structures exposed to fluctuating water levels.
    X3
    ta
    Aggressive exposure Permanently submerged or wet (rarely dry).
    Concrete in contact with groundwater including capillary rise zone,
    qa
    concrete containing or permanently exposed to saline water.
    X4 Severe exposure Moderate humidity. External concrete within 1km from
    the sea or in contact with high saline water table or sabkhas. Concrete not
    as

    affected by condensation, irrigation or leakage, which are more than 3m


    above ground level.
    se

    X5 Extreme exposure Cyclic wet and dry. External concrete within 1km from
    the sea or in contact with high saline groundwater or sabkhas. Concrete
    er

    affected by condensation, irrigation or leakage, which are less than 3m


    above ground level or within capillary zone. Concrete surfaces exposed to
    sea water splash or in sea water tidal zone.
    ov
    o

    Table 6.2.
    it

    Sulphate exposure classes


    et

    1
    Sulphate and magnesium Natural soil Brownfield
    m

    Exposure
    2:1 water/soil or groundwater Static
    class Static Mobile Mobile
    2 water 2
    water pH water pH water pH
    SO4 (mg/l) Mg (mg/l) pH

    S1 < 1500 > 3.5 Not mobile > 5.5 Not mobile
    S2 1500-3000 > 3.5 Not mobile > 5.5 Not mobile
    S3 3001-6000 1000 > 3.5 Not mobile > 5.5 Not mobile
    S4 > 6000 1000 > 3.5 > 5.5 > 5.5 > 6.5
    S5 > 6000 > 1000 > 3.5 > 5.5 > 5.5 > 6.5

    Notes
    1. Brownfield sites are those previously occupied and contain chemical residues into the ground
    or groundwater
    2. The mobility of water shall be determined as described in the Concrete Society CS 163.
    QCS 2014 Section 05: Concrete Page 12
    Part 06: Property Requirements

    6.3 FRESH CONCRETE

    6.3.1 General

    1 Where adequate workability is difficult to obtain at the maximum water/cementitious ratio


    allowed, the use of plasticisers or water reducing admixtures may be considered.
    Alternatively an increase in cementitious content may be considered where this will not
    adversely affect the durability of the concrete.

    3
    2 Cementitious contents in excess of 400 kg/m shall not be used unless special consideration
    has been given to the effect for heat of hydration and reduce thermal stress in the concrete,
    and approval has been obtained from the Engineer. The maximum cementitious content shall
    not exceed 500kg/m

    .
    3 The proportioning, mixing and placing of the mixture shall be in accordance with Parts 7 and

    l
    .l.
    8 of this Section

    rw
    4 Temperature (at placement):

    (a) Maximum fresh concrete temperature shall not exceed 32C unless construction

    ta
    testing to verify a proposed concrete mixture will function satisfactorily at a concrete
    qa
    temperature greater than 32C. No concrete shall be placed if the concrete
    temperature is above 35C
    (b) For mass concrete, the concrete producer shall demonstrate that temperature of
    as

    concrete due to hydration shall comply with the maximum fresh concrete temperature
    specified. The supplier may use in his demonstration testing heat sensors and
    se

    simulation technologies which measure the concrete heat of hydration and its rate
    versus concrete curing age.
    er

    5 The Contractor is responsible for ensuring that the concrete is able to be fully compacted
    ov

    within the concrete element regardless of reinforcing density or other limitations. This may
    involve reducing the maximum aggregate size, increase the level of concrete workability or
    o

    use self-compacting concrete.


    it
    et

    6 Where the consistence of concrete is to be determined, it shall be measured either by means


    of:
    m

    (a) Slump test conforming to BS EN 12350-2


    (b) Flow table test conforming to BS EN 12350-5

    7 The consistence of concrete shall be determined at the time of use of the concrete or in the
    case of ready-mix concrete, at the time of delivery.

    8 The tolerances for the different consistence tests and target values are given in Table 6.3.
    Table 6.3.
    Tolerances for target values of consistence
    Target value (mm) 40 50 to 90 100
    Slump*
    Tolerance (mm) -30, +40 -40, +50 -50, +60
    Target value (mm) All values
    Flow diameter*
    Tolerance (mm) -60, +70

    * For spot samples taken from initial discharge.


    QCS 2014 Section 05: Concrete Page 13
    Part 06: Property Requirements

    6.4 GRADES OF CONCRETE

    1 Where strength is classified with respect to compressive strength, Table 6.4 gives the
    concrete grade with the requirements for w/c ratio and cementitious content.

    2 The characteristic compressive strength at 28 days of 150mm cubes (f ck, cube) or 150mm
    diameter by 300mm cylinders (fck, cyl) may be used for the classification.

    3 Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where
    testing shall be requested at 56 days, or 90 days as approved by the Engineer.

    Table 6.4:
    Concrete grades and composition requirements

    l .
    .l.
    Minimum Maximum
    Concrete Grade

    Minimum
    characteristic Minimum cementitious
    characteristic cube Water : Cementitious

    rw
    cylinder strength content
    strength (fck, cube) Ratio
    (fck, cyl)

    (N/mm )
    2
    (N/mm )
    2

    ta
    (kg/m )
    3
    (w/c)
    qa
    B 15 15 12 - -
    as

    B 20 20 16 - -

    C 25 25 20 260 0.60
    se

    C 30 30 25 300 0.58
    er

    C 35 35 28 320 0.55

    C 40 40 32 335 0.50
    ov

    C45 45 35 355 0.47


    o

    C 50 50 40 370 0.45
    it

    C 60 60 50 380 0.40
    et

    C 75 75 60 390 0.35
    m

    6.5 DURABILITY REQUIREMENTS

    6.5.1 General

    1 Constituent materials shall not contain harmful ingredients in such quantities as may be
    detrimental to the durability of concrete or cause corrosion of the reinforcement.

    2 For reinforced concrete in the ground, the need for protection from chlorides must be
    balanced against the need for protection from sulphates.

    3 Protective measures include the use of surface treatment, alternative reinforcement and
    increasing the concrete cover. In every case, the need for good quality concrete with low
    permeability is paramount.
    QCS 2014 Section 05: Concrete Page 14
    Part 06: Property Requirements

    6.5.2 Maximum acid soluble chloride content

    1 The chloride content of the concrete, expressed as the percentage of chloride ions by mass
    of cementitious materials, shall not exceed the values given in Table 6.5.

    2 Calcium chloride and chloride based admixtures shall not be used in concrete containing
    steel reinforcement or other embedded metal.

    3 The determination of the chloride content in the concrete shall be conducted by the sum of
    the contributions from the constituent materials as described in BS EN 206-1 and BS 8500-2.

    Table 6.5.
    Maximum chloride content of concrete (by weight of cementitious materials)
    Concrete made with sulphate Concrete made with other cementitious

    .
    Concrete type
    resisting Portland cement materials than SRPC

    l
    .l.
    Reinforced concrete 0.15 % 0.3 %

    rw
    Pre-stressed concrete 0.08 % 0.10 %

    6.5.3 Type of cementitious material


    ta
    qa
    1 Different types of cementitious materials offer different resistance to sulphate attack and
    penetration of chlorides
    as

    2 The minimum cementitious content for different concrete grades is given in Table 6.4.
    se

    3 Table 6.6 gives the different types of cementitious materials and their combinations.
    er

    Table 6.6.
    ov

    Cementitious materials and combinations


    BS EN 197-1 ASTM
    Cementitious material Percentage of components
    designation standard
    it o

    Portland cement 100% PC CEM I Type 1


    et

    Sulphate-resistance Portland
    100% SRPC - Type 5
    m

    cement
    65-79% PC
    PC/fly ash CEM II/B-V
    35-21% FA

    PC/ground granulated 35-65% PC


    CEM III/A
    blastfurnace slag 65-35% GGBS

    55-70% PC
    Triple blend
    35-25% FA
    PC/FA/SF
    10-5% SF
    30-45% PC
    Triple blend PC/GGBS/SF 60-50% GGBS
    10-5% SF
    QCS 2014 Section 05: Concrete Page 15
    Part 06: Property Requirements

    6.5.4 Resistance to alkali-silica reaction

    1 Alkali-silica reaction is the most common form of alkali-aggregate reaction.

    2 Dry concrete is not prone to cracking by alkali-silica reaction, as it needs an external source
    of water to develop sufficiently to cause cracking.

    3 Where aggregate contain varieties of silica susceptible to attack by alkalis from cement and
    other sources and the concrete is exposed to humid conditions, actions shall be taken to
    prevent deleterious alkali-silica reaction using recommendations and procedures given in BS
    EN 206-1 and BS 8500-2.

    6.5.5 Recommendations to resist reinforcement corrosion

    1 Durability design should start at the concept design stage, continuing through the design,

    l .
    detailing, specification and execution phases.

    .l.
    rw
    2 This section covers the concrete grade, cementitious type, and minimum concrete cover for
    various exposure classes as given in Table 6.1.

    3
    ta
    Table 6.7 provided recommended values of concrete grade and cover thickness to resist
    reinforcement corrosion at different exposure classes.
    qa
    Table 6.7.
    as

    Recommended durability requirement to resist reinforcement corrosion


    se

    Cementitious type
    Exposure Class Minimum concrete cover (mm)
    (Table 6.6)
    er

    No risk of
    ov

    X0 25 All
    corrosion
    o

    X1 Mild 45 40 35 30 All
    it
    et

    X2 Moderate - 50 45 40 35 All
    m

    PC/FA
    X3 Aggressive - 70 65 60 55 PC/GGBS
    Triple blend
    PC/FA
    X4 Severe* - 75 70 65 60 PC/GGBS
    Triple blend

    X5 Extreme* - 80 75 70 65 Triple blend

    Minimum concrete
    C30 C40 C50 C60 C75
    grade
    *High level of cement replacement is required for severe and extreme exposure conditions.
    Other protection measures such as coated reinforcement or surface treatment may be
    considered.
    QCS 2014 Section 05: Concrete Page 16
    Part 06: Property Requirements

    6.5.6 Recommendations to resist sulphate attack

    1 The exposure classification shall be identified based on the sulphate and magnesium
    contents in the ground and groundwater, pH and mobility of groundwater as given in Table
    6.2.

    2 The recommended concrete specification requirements in terms of concrete grade and


    cementitious type are given in Table 6.8.

    3 Unless stated otherwise by the Engineer or project designs, all concrete below ground shall
    have surface protection to prevent the movement of moisture from the ground, through the
    foundations into the superstructure. The method of protection shall be in accordance with
    Section 15 of the QCS or as approved by Qatar Standards.

    .
    Table 6.8

    l
    .l.
    Recommended durability requirement to resist sulphate attack

    rw
    Exposure class Minimum concrete grade Cementitious type

    S1 C35 ta All
    qa
    C40 Triple blend
    S2
    C50 SRPC, PC/FA, PC/GGBS
    as

    C50 Triple blend


    S3
    se

    C60 SRPC, PC/FA, PC/GGBS


    C60
    S4 Triple blend
    er

    C75
    ov

    1
    S5 See Note See Note

    Note:
    1
    S5 requires special treatment when the sulphate content exceeds 6000 mg/l and the magnesium
    o

    content exceeds 1000 mg/l.


    it
    et

    6.5.7 Durability-Related Properties


    m

    1 The durability of concrete is greatly influenced by the ability of the concrete cover to resist the
    movement of liquid and gas through concrete.

    2 The commonly used test for assessing the transport properties of concrete are listed in Table
    6.9 together with typical values. Lower value indicates more durable concrete.

    3 No values are currently specified for various exposure classes, but may be requested by the
    Engineer. Table 6.9 gives the recommended durability-related properties and typical values
    for the development of mix design and comparative performance as given in the Concrete
    Society CS163.

    4 For Severe and Extreme exposures, it is recommended to use high durable concrete (Table
    6.9)
    QCS 2014 Section 05: Concrete Page 17
    Part 06: Property Requirements

    Table 6.9
    Recommended properties and typical values for concrete
    Age range between 28 and 90 days
    Concrete property Test method
    High durability Minimum durability
    Water absorption BS 1881: Part 122 2% 4%
    Water penetration, BS EN 12390-8 5 mm 30 mm
    Rapid chloride permeability (RCP), ASTM C 1202 500 coulombs 4000 coulombs
    -12 2 -12 2
    Chloride migration NT Build 492 2.0 x10 (m /s) 9.0 x10 (m /s)

    1. Concrete shall be tested for any of the transport properties when requested by the Engineer and shall
    be tested at 28 days.

    2. Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing
    shall be requested at 56 days, or 90 days.

    l .
    .l.
    6.6 DESIGN OF CONCRETE MIXES

    rw
    1 At the start of the construction period, the Contractor shall design a mix for each grade of
    concrete as stated hereafter.

    2 Each mix design shall be such that: ta


    qa
    (a) the aggregate shall comprise fine aggregate and coarse aggregate with size specified
    in Section 5, Part 2.
    as

    (b) the combined aggregate grading shall be continuous


    se

    (c) the aggregate quantity shall be calculated by weight.

    3 Where a concrete production facility has strength test records not more than 12 months old,
    er

    a sample standard deviation, Ss, shall be established. Test records from which Ss is
    calculated shall consist of at least 30 consecutive tests or two groups of consecutive tests
    ov

    totalling at least 30 tests


    o

    4 Where a concrete production facility does not have strength test records meeting
    it

    requirements of 6.6 (3) above, but does have test records not more than 12 months old
    et

    based on 15 to 29 consecutive tests, a sample standard deviation Ss shall be established as


    the product of the calculated sample standard deviation and modification factor of Table 6.10
    m

    Table 6.10
    Modification Factor for Sample Standard Deviation When Less Than 30 Tests Are Available
    Modification factor for sample standard
    No. of tests
    deviation
    Less than 15 Use para 7. Below
    15 1.16
    20 1.08
    25 1.03
    30 1.00
    1- Interpolate for intermediate number of tests
    2- Modified sample standard deviation, Ss, to be used to determined required
    average strength fcr
    QCS 2014 Section 05: Concrete Page 18
    Part 06: Property Requirements

    5 To determine the correction factor between cube strength and cylinder strength, the
    contractor shall establish at least 30 consecutive strength tests from each proposed mix
    design. This correction will remain valid thru the project providing that no change in the
    properties of the materials and no change in source occurred.

    6 Required average compressive strength (Target Mean Strength) fcr used as the basis for
    selection of concrete proportions shall be determined from Table 6.11 using the sample
    standard deviation, Ss

    Table 6.11:
    Required Target Mean Strength when data are available
    to establish a sample Standard Deviation

    .
    Specified compressive strength, Required average compressive strength, Target

    l
    2

    .l.
    N/mm2 or MPa Mean Strength, N/mm or MPa

    rw
    Fc < 35 MPa --- see footnote Fcr = fc + 1.34Ss ------------------ Eq. 1

    ta
    Fcr = fc + 2.33Ss 3.5 ---------- Eq. 2
    qa
    Fc > 35 MPa --- see footnote Fcr = fc + 1.34Ss ------------------ Eq. 1

    Fcr = 0.90fc + 2.33Ss ------------ Eq. 3


    as

    Note: Use the larger value computed from any equation


    se

    7 When a concrete production facility does not have field strength test records for calculation of
    Ss, Required average strength (Target Mean Strength) fcr shall be determined as follow:
    er
    ov

    (a) Fcr = fc + 8.5 MPa when 20 < fc < 35 MPa


    (b) Fcr = 1.10fc + 5 MPa when fc > 35 MPa
    it o
    et

    6.6.1 Concrete
    m

    1 Portland cement concrete shall consist of a mixture of cementitious materials, fine aggregate,
    coarse aggregate, water, and additives (when required). It shall be classified as in Table 6.4
    unless otherwise stated hereafter and requested by the Engineer.

    2 Blinding concrete

    (a) Blinding concrete shall be of minimum Grade C15 and above.


    (b) The thickness of the blinding concrete shall be as shown on the Drawings, but shall in
    no instance be less than 75 mm.

    (c) The surface finish to blinding concrete shall be Class U4 as specified in Clause 9.3.1
    of Part 9 of this Section or as directed by the Engineer.
    QCS 2014 Section 05: Concrete Page 19
    Part 06: Property Requirements

    3 Mass Concrete

    (a) The fresh concrete temperature at placing shall not exceed 21C to minimise thermal
    cracking. A higher temperature of up to 27C may be accepted with a demonstration of
    the satisfactory performance of concrete including mock up and thermal calculations.
    The maximum allowable differential temperature between the interior and the exterior
    of the mass concrete element shall not exceed 20 C. The maximum temperature in
    any location within the mass concrete structure during curing shall not exceed 70 C.
    The drop in concrete surface temperature during, and at the conclusion of the
    specified curing period, shall not exceed 11 C in any 24 hour period.

    4 Self-Compacting Concrete

    (a) General: Self-Compacting Concrete (SCC) is a special concrete that requires


    minimum or no vibration for placing and compaction. It is able to flow under its own

    .
    weight, completely filling formwork and achieving full compaction, even in the presence

    l
    .l.
    of congested reinforcement. The hardened concrete is dense, homogeneous and has
    the same engineering properties and durability as traditional vibrated, fully compacted

    rw
    concrete.
    (b) Self-Compacting Concrete Supplier: SCC shall be supplied by a competent concrete

    ta
    producer with a record of successfully producing this type of concrete at considerable
    volume and with high consistency.
    qa
    (c) Constituent Materials, General: The constituent materials for SCC are the same as
    those used in traditional concrete conforming to EN 206-1, as specified in part 2 of this
    as

    section.
    se

    (d) To achieve these requirements the control of the constituent materials needs to be
    increased and the tolerable variations restricted, so that daily production of SCC is
    within the conformity criteria without the need to test and/or adjust every batch.
    er

    (e) Recommended Test Requirements for SCC:


    ov

    Laboratory tests Field Tests


    o

    Slump-flow 600 750 mm 550 750 mm


    it
    et

    V-Funnel 6 25 sec N.A


    m

    L-Box (3 bars) > 0.80 N.A


    J-Ring < 10mm N.A
    (f) Concrete specimens shall be moulded in single layer without rodding and tapping
    (g) Slump flow and VSI testing shall be performed as outlined in the European Guidelines
    for SCC, BS EN 12350-8 and BS EN 12350-9 or ACI 237R 07 and ASTM C 1611/C
    1611M

    5 Pile Concrete
    3
    (a) The cementitious content shall not be less than 380 kg/m , as specified in Section 4.
    (b) The water-cementitious ratio shall not exceed 0.45
    QCS 2014 Section 05: Concrete Page 20
    Part 06: Property Requirements

    (c) The concrete mixture shall be designed of high slump not less than 150 mm allowing
    proper free fall with excellent homogeneity. When concrete mixture requires slump of
    greater than 230 mm, it shall be designed as Self-Compacting Concrete or as
    instructed by the Engineer.
    (d) The concrete slump shall have adequate workability retention using approved type of
    retarder and shall be submitted in the design mix.
    (e) The increase in workability shall not permit any decrease in the specified design
    strength
    (f) The concrete in a pile shall, if at all possible, be placed in one continuous operation.

    6 Underwater Concrete

    (a) Shall comply with ACI 304 Chapter 8

    l .
    3

    .l.
    (b) The Cementitious content shall not be less than 390 kg/m

    rw
    (c) The water-cementitious ratio must not exceed 0.40
    (d) Fine aggregate contents of 45 to 55% by volume of total aggregate and air contents of

    (e) ta
    up to approximately 5% are generally specified.
    Concrete shall be more cohesive and less prone to washout of cement or fines from
    qa
    the concrete during placement. Antiwashout admixtures or alternative concrete mix
    shall be used for underwater concrete.
    as

    (f) Trial placements shall be conducted to verify that the concrete proportioned with the
    antiwashout admixture can maintain adequate slump life and can flow for the required
    se

    distance.
    er

    (g) The concrete mixture shall be designed of high slump not less than 150 mm allowing
    proper free fall with excellent homogeneity. The use of air-entraining admixture shall
    ov

    be evaluated as it increases the workability. When concrete mixture requires slump of


    greater than 230 mm, it shall be designed as Self Compacted Concrete. The increase
    in slump shall be made using proper admixtures.
    it o

    (h) The concrete slump shall have adequate retention using approved type of retarder and
    et

    shall be submitted in the design mix.


    (i) The increase in workability shall not permit any decrease in the specified design
    m

    strength
    (j) The concrete shall be placed in one continuous operation
    (k) The final selection of a concrete mixture shall be based on test placements made
    under water in a placement box or in a pit that can be dewatered after the placement.
    Test placements shall be examined for concrete surface flatness, amount of laitance
    present, quality of concrete at the extreme flow distance of the test, and flow around
    embedded items, if appropriate.

    7 Shotcrete

    (a) The classification of shotcreting shall be in accordance to the process used (wet-mix
    or dry-mix) and the size of aggregates used.
    (b) All materials shall be as per QCS except for aggregate where gradation shall be as per
    ACI 506R and 506.2R
    QCS 2014 Section 05: Concrete Page 21
    Part 06: Property Requirements

    (c) Steel and synthetic fibers will be used to reduce propagation of cracks. Fibers shall be
    as per Manufacturer supplier data sheet and shall conform to ASTM A 820 for steel
    fibers and ASTM C1116 for synthetic fibers.
    (d) The nozzle operator should be certified (refer to ACI CP-60) and have completed at
    least one similar application as a nozzle operator on a similar project. The nozzle
    operator should also be able to demonstrate, by test, an ability to satisfactorily perform
    the required duties and to apply shotcrete as required by specifications
    (e) Before shotcreting the surface shall be prepared and maintained before and during
    shotcrete application. Surface preparation shall conform to ACI 506 R chap. 5
    3
    (f) The cementitious content shall not be less than 360 kg/m where wet-mix is applied
    the slump shall be in the range of 40 to 80 mm
    (g) Normal testing ages for compressive strength are 7 and 28 days; however, shorter
    periods may be required for particular applications or conditions as directed by the

    l .
    3
    Engineer. Testing shall be on daily production or every 30 m whichever is greater.

    .l.
    (h) Sampling and testing, however, should be varied according to the size and complexity

    rw
    of the project. Sampling should be done in accordance with ASTM C 1385. Making
    extra cylinders or panels shall be at the request of Engineer if testing results vary.
    (i)
    ta
    Testing for water absorption and drying shrinkage shall be at the request of the
    qa
    Engineer.
    (j) Fiber-reinforced shotcrete requires fiber washout tests or flexural toughness testing
    according to ASTM C 1018.
    as

    (k) Acceptance of shotcrete should be based on results obtained from drilled cores or
    se

    sawed cubes (ASTM C 42). The use of data from nondestructive testing devices, such
    as impact hammers or probes (ASTM C 805, ASTM C 803), ultrasonic equipment
    er

    (ASTM C 597), and pull-out devices (ASTM C 900) may be useful in determining the
    uniformity and quality of the in-place shotcrete. These tests, however, may not provide
    ov

    reliable values for compressive strength.


    (l) Core grading is a method used to evaluate encasement of reinforcement. Core
    o

    grading shall be used for nozzle operator evaluation. Core grading should not be used
    it

    to evaluate structures.
    et

    8 No-Fines Concrete and Pervious concrete


    m

    (a) No-fines concrete shall be made using a coarse aggregate conforming QCS section 5
    part 3
    (b) Proportion of aggregate, cement and water shall be determined by trial mixes by the
    Contractor and to be accepted by the Engineer.
    (c) All the aggregate particles are to be coated with a film of cement grout.
    (d) No-fines concrete when placed shall contain no layers of laitance.
    (e) No-fines concrete shall not be mixed by hand.
    (f) Mechanical vibration shall not be used to compact no-fines concrete.
    (g) Three test cubes of no-fines concrete shall be made of each preliminary mix.
    (h) Minimum crushing strength of the chosen mix shall be 5 MPa at 28 days.
    QCS 2014 Section 05: Concrete Page 22
    Part 06: Property Requirements

    (i) The porosity of no-fines concrete shall be such that water will pass through a slab
    2
    300 mm thick at the rate of not less than 7 l/m s of slab with a constant 100 mm
    depth of water on the slab.
    (j) Where a slab incorporating vertical weep holes or drain holes is casted above a layer
    of no-fines concrete; any polyethylene sheeting shall be pierced below the pipes
    forming such drain holes and the edges of the sheeting sealed to the lower end of the
    pipe to prevent the ingress of grout and fine particles from the slab concrete into the
    no-fines concrete.
    (k) The limit for the maximum height of drop while placing is not applicable for no fines
    concrete.
    (l) Formwork shall remain in place until the no fines concrete has gained adequate
    strength to support itself as per the requirements of Part 10 of this Section.

    .
    (m) Curing shall be carried out in accordance with the provisions of Part 11 of this Section

    l
    .l.
    (n) The fresh density of Pervious concrete shall be tested as per ASTM C1688 and the

    rw
    infiltration rate shall be tested as per ASTM C1701 and to follow ACI 522.1R for testing
    and quality control scheme.

    9
    ta
    Concrete with recycled aggregates shall be generally approved once the source of recycled
    aggregates is identified based on type and approved by the Engineer.
    qa
    (a) The recycled aggregates shall meet with BS EN 12620 and QCS requirements.
    as

    (b) The concrete made with recycled aggregates shall be limited to design strength of C40
    MPa cube strength; unless otherwise accepted by the Engineer. BS EN 206-1 shall be
    se

    the code of practice and guide for the usage of recycled concrete aggregates in
    concrete or ACI 555 and BRE digest 433.
    er

    (c) The Water-cementitious ratio shall not exceed 0.50


    ov

    (d) To determine a target mean strength on the basis of a required strength, a higher
    standard deviation (increased by 40%) shall be used when designing a concrete with
    recycled aggregates of variable quality than when recycled aggregate of uniform
    o

    quality or virgin aggregates are used


    it

    (e) Specific gravity, unit weight, and absorption of aggregates should be determined
    et

    before mixture proportion studies


    m

    (f) The mixture proportion should be based on the measured density of the recycled
    aggregates intended in the job concrete
    (g) Trial mixes shall be made to verify the requirements with project specification and
    QCS.

    10 Heavyweight and radiation shielding concrete

    (a) The quality of the aggregates should comply with the requirements of QCS for normal
    weight aggregates, ASTM C 637 for heavyweight aggregates and ASTM C638 for
    aggregates to be used in radiation-shielding concrete.
    (b) When ferrophosphorous aggregates are used, tests shall be made to determine if
    gases (nontoxic) might be released during construction.
    (c) Aggregates shall be checked for every delivery to ensure that they conform completely
    with purchase specifications
    QCS 2014 Section 05: Concrete Page 23
    Part 06: Property Requirements

    (d) Aggregates shall be frequently evaluated for the effects of deleterious substances or
    aggregate coatings on concrete strength or the promotion of corrosion in metallic
    aggregates or embedments
    (e) The chemical properties of all high-density aggregates must be provided to the
    Engineer for evaluation before use with due consideration given to chemical reactivity,
    particularly in highly alkaline environment as found in cement paste.
    (f) Tests for alkali-aggregate reactivity shall be determined from each source and supplier
    and shall be made every 3 months.
    (g) The fresh density of high-density concrete shall be made from each truck
    (h) Lead shot concrete shall not be use for structural concrete.
    (i) Thermal conductivity, elastic behaviour and shrinkage, hardened density, strength as
    well as other hardened concrete properties shall be tested and verified before the use

    .
    of concrete.

    l
    .l.
    11 Fiber-Reinforced Concrete

    rw
    (a) Classification of fiber-reinforced concrete shall be made based on the material type of
    the fiber incorporated:
    (i) ta
    Type I Steel Fiber-Reinforced ConcreteContains stainless steel, alloy steel, or
    qa
    carbon steel fibers conforming to Specification of BS EN 14889-1 or ASTM
    A820 /A820M .
    as

    (ii) Type II Glass Fiber-Reinforced ConcreteContains alkali-resistant (AR) glass


    fibers conforming to Specification C 1666/C 1666M.
    se

    (iii) Type III Synthetic Fiber-Reinforced Concrete Contains synthetic fibers for
    which documentary evidence can be produced confirming their long-term
    er

    resistance to deterioration when in contact with the moisture and alkalis present
    in cement paste and the substances present in admixtures and shall conform to
    ov

    BS EN 14889-2
    (iv) Type IV Natural Fiber-Reinforced Concrete Contains natural fibers for which
    o

    documentary evidence can be produced confirming their long-term resistance to


    it

    deterioration when in contact with the moisture and alkalis present in cement
    et

    paste and the substances present in admixtures. Test Method ASTM D 6942
    m

    shall be used to determine the susceptibility of these fibers to deterioration as a


    result of exposure to alkalis in concrete
    (v) When the purchaser chooses to permit the use of fibers other than those
    complying with the above classifications, the manufacturer or supplier shall
    show evidence satisfactory to the purchaser that the type of fiber proposed for
    use shows long-term resistance to deterioration when in contact with the
    moisture and alkalis present in cement paste and the substances present in
    admixtures
    (b) The contractor shall submit:
    (i) Type of fiber-reinforced concrete required
    (ii) Designated size, or sizes, of coarse aggregates
    QCS 2014 Section 05: Concrete Page 24
    Part 06: Property Requirements

    (c) Slump or time of flow required at the point of delivery, or when appropriate the point of
    placement, subject to the tolerances hereinafter specified Slump shall be specified
    when it is anticipated to be 50 mm or more. Except as otherwise specifically permitted
    by the Engineer, cement, supplementary cementitious materials, fine and coarse
    aggregates, mixing water, and admixtures shall be measured in accordance with the
    applicable requirements of QCS
    (d) Fibers shall be measured by mass. When the fibers are to be measured by mass,
    bags, boxes, or like containers are acceptable provided that such like containers are
    sealed by the fiber manufacturer and have the mass contained therein clearly marked.
    No fraction of a container delivered unsealed, or left over from previous work, shall be
    used unless weighed.
    (e) Prepackaged, dry, combined materials, including fibers, shall comply with the
    packaging and marking requirements of Specification ASTM C 387 or C 1480 and
    shall be accepted for use provided that after addition of water, the resulting fiber

    l .
    reinforced concrete meets the performance requirements of this specification

    .l.
    (f) Batching plant used for the preparation of continuously mixed fiber-reinforced concrete

    rw
    shall comply with the applicable requirements of NRMCA. Fiber-reinforced concrete
    shall be added directly to the concrete at the time of batching in amounts in accord

    ta
    with approved submittals for each type of concrete required. Mix concrete in strict
    accord with fiber-reinforced concrete manufacturer, instructions and recommendations
    qa
    (g) Fiber-reinforced concrete shall be free of fiber balls when delivered
    (h) The manufacturer of the fiber-reinforced concrete shall furnish to the purchaser a
    as

    delivery ticket or statement of particulars on which is printed, stamped, or written,


    information with details of the type, brand, and amount of fibers used.
    se

    (i) The contractor shall afford the inspector all reasonable access, without charge, for the
    er

    procurement of samples of freshly mixed fiber-reinforced concrete at the time of


    placement to determine compliance with the requirements of this specification.
    ov

    (j) Samples of batch-mixed fiber-reinforced concrete shall be obtained in accordance with


    Practice ASTM C 172 or C 1385/C 1385M for shotcrete as appropriate, except that
    o

    wet-sieving shall not be permitted. Sampling for uniformity tests shall be in accordance
    it

    with specification ASTM C 94/C 94M


    et

    (k) If the measured slumps, time of flow, or air content fall outside the limits permitted by
    m

    this specification, make a check test immediately on another portion of the same
    sample. If the results again fall outside the permitted limits, the material represented by
    the sample fails to meet the requirements of this specification
    (l) The following shall apply to all forms of fiber-reinforced concrete except dry-mix
    shotcrete. When applicable, the slump shall be in tolerance with this section para
    6.4.2.5 (a) and (b).
    (m) The time of flow shall be in the tolerances as follow:
    (i) When the project specifications for time of flow are written as a minimum or
    not less than requirement

    Specified time of flow


    If 15sec or less If more than 15 sec
    Plus Tolerance 5s 10s
    Minus Tolerance 0s 0s
    QCS 2014 Section 05: Concrete Page 25
    Part 06: Property Requirements

    (ii) When the project specifications for time of flow are not written as a minimum
    or not less than requirement:
    Tolerances for time of flow
    For specified time of flow Tolerance
    8 to 15 s + 3s
    More than 15 s + 5s

    (n) Finishability - Pre-project trials shall be utilized to determine acceptable surface


    finishability by the Engineer. The manufacturer shall provide the services of a qualified
    technician to instruct the concrete supplier in proper batching and mixing of materials
    to be provided.
    (o) Provide fibers for concrete reinforcing capable of achieving a two hour fire resistance
    rating when tested under ASTM E 119. Fire tests must be certified.

    .
    12 Lightweight concrete

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    .l.
    (a) This clause of the specification refers to lightweight concrete with improved insulation

    rw
    properties where the practical range of densities is between about 300 and 1850
    kg/m3.
    (b) The required density and strength of the lightweight concrete will be specified on the
    drawings or directed by the Engineer.
    ta
    qa
    (c) The method of production of lightweight concrete will be shown on the drawings or
    directed by the Engineer. The Contractor shall submit full technical details of the
    materials and method of production for the lightweight concrete along with a list of
    as

    previous projects where the particular system has been used.


    (d) After source approval of the material and system the Contractor shall submit a mix
    se

    design for the lightweight concrete for the approval of the Engineer. After the review
    and approval of the mix theoretical mix design the Contractor shall carry out a trial mix
    er

    to check the workability of the fresh concrete and to allow samples to be made for
    compressive strength and density.
    ov

    (e) The Engineer may also instruct that tests are carried out for abrasion resistance and
    thermal insulation properties.
    o

    (f) Iightweight concrete shall be made with lightweight aggregates as approved in part 2 of
    section 05 in QCS for its use in concrete
    it
    et

    (g) The performance of lightweight concrete shall follow ACI 213R


    m

    6.7 TRIAL MIXES


    1 As soon as the Engineer has approved the concrete mix design for each grade of concrete
    and during or following the carrying out of the preliminary tests, the Contractor shall prepare a
    trial mix of each grade in the presence of the Engineer at least 35 days before
    commencement of concreting. Trial mix shall be mixed and handled by means of the same
    plant which the Contractor proposes to use in the Works. The trial mix shall comprise not
    3
    less than 50% from the central mixing drum capacity but not less than 3.0 m of concrete.
    The trial mix can be exempted if concrete supplier provides through an independent
    approved testing agency adequate history on strength:

    (a) Not less than 30 strength test results as in para 6.6 of this specification
    (b) The results shall valid by no more than 6 months from the date of approval

    2 Batch the field concrete trial mixture within -5C of the proposed maximum allowable fresh
    3
    concrete temperature in a truck-mixer with a minimum batch size of 3 m .
    QCS 2014 Section 05: Concrete Page 26
    Part 06: Property Requirements

    3 The concrete mixture shall be held in the mixer for 120 minutes, unless otherwise specified
    by the Engineer. During the entire 120-minute period, agitate the mixer at 1 to 6 rpm. At the
    end of 120 minutes, mix the concrete mixture at full mixing speed designated by the
    manufacturer (6 to 18 rpm) for 2 minutes.

    4 For each trial mix, a plant production trial shall be carried out and the slump of the concrete
    checked immediately after discharge from the mixer and thereafter at 30 min intervals up to
    the maximum time period envisaged for delivery and standing on site. Based on this trial the
    mix design shall identify any adjustments to the range of plasticiser for acceptable workability
    for different times after batching. Where ready mix concrete is being used, the above
    requirement may be waived at the discretion of the Engineer if the Contractor has
    documented previous experience of a particular mix design with test results available.

    5 The proportions of cement, aggregate and water shall be carefully determined by weight in
    accordance with the Contractor's approved mix design (or modified mix design after
    preliminary tests).

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    6 Each sample shall consist of at least 9 specimens for strength analysis where 3 specimens
    for each age will be tested to determine the concrete strength at the required age.

    rw
    7 If either or both the average value of the strength of the three cubes tested at 28 d is less
    than the required strength (target strength) or the difference between the greatest and the

    ta
    least strengths is more than 15 % of the average strengths, as per BS EN 206-1, the
    qa
    Contractor shall take measures as deemed necessary such as:

    (a) Propose new mix design


    as

    (b) Provide new materials and prepare and test further trial mixes until specified
    requirements are achieved.
    se

    8 Additionally, the Contractor shall measure the temperature, workability of concrete in each
    batch.
    er

    3
    9 When requested by engineer, a mock-up of 2x2x2 m shall be made at jobsite and full scale
    ov

    tests of the workability of each trial mix shall be made by the Contractor in the presence of
    the Engineer. The following tests shall be made on the Site by filling trial moulds to confirm
    the suitability of:
    it o

    (a) mix for the works


    et

    (b) type of plant used for mixing


    m

    (c) face intended for use in the works


    (d) type of form oil
    (e) type of protective coatings.

    10 Redesign of the concrete mixes and trial mixes of concrete shall be repeated for each grade
    of concrete until the concrete meets the requirements in this specification and it is verified by
    full scale mockup test as described above.

    11 Approval of the job-mix proportions by the Engineer or his assistance to the Contractor in
    establishing those proportions, in no way relieves the Contractor of the responsibility of
    producing concrete which meets the requirements of this Specification.

    12 All costs connected with the preparations of trial mixes and the design of the job mixes shall
    be borne by the Contractor.

    13 The Contractor shall declare any change in the source of the material and any changes in the
    cement content consumption greater than 20.0kg/m from that used in the trial mixes.
    QCS 2014 Section 05: Concrete Page 27
    Part 06: Property Requirements

    6.8 QUALITY AND TESTING

    6.8.1 General

    1 In order to ensure that the quality of materials and mix proportions are maintained throughout
    concreting operations, sampling and testing shall be carried out using the relevant standard
    procedures and all other relevant codes quoted in this specification in accordance with a
    routine testing program that shall be agreed with the Engineer before the start of concrete
    work.

    2 The Contractor, through a third party approved testing agency, shall supply all necessary
    tools for tests, shall cast all concrete specimens, strip and store them in water as stated in
    BS EN 12390-2. The Contractor shall also arrange for the transport of samples to the place
    of testing and shall supply the Engineer with duplicate copies of all test certificates.

    6.8.2 Tests for Concrete

    l .
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    1 Unless the Engineer directs otherwise, the program shall include at least the tests specified
    below.

    rw
    2 Tests on aggregates shall be as described in Part 2 of this Section.

    3
    ta
    Concrete shall be tested in accordance with the requirements of this specification by qualified
    field testing technicians or engineer. Concrete testing laboratory personnel shall be certified
    qa
    from a recognised Institution. Field personnels in charge of sampling concrete; testing for
    slump, and temperature; and making and curing test specimens shall be certified from a
    recognised Institution too.
    as

    4 Slump tests (and VSI testing when applicable) shall be carried out at the rate of one test per
    se

    3
    load of concrete delivered to the Site, or one test per 10 m whichever is the lesser for the
    3 3
    first 50 m of concrete then at a rate of 1 slump test for every 50 m if concrete was
    er

    consistent during production. In the event of inconsistent slump values, the Engineer may
    instruct the Contractor to check the slump test on each truck of concrete at the plant. The
    ov

    Contractor shall carry out an investigation to establish the cause of the high variation in slump
    and shall take any necessary corrective measures. The slump requirements for the fresh
    concrete are to be approved by the Engineer.
    it o

    5 The adjustment for the slump of concrete to fit the job requirement can be conducted only
    one time using a proper additive at jobsite provided that such addition does not increase the
    et

    water-cement ratio and setting time above the maximum permitted by the specifications. This
    m

    addition will only be made at the approval of Engineer.

    6 Concrete shall be available within the permissible range of slump for a period of 30 min
    starting either on arrival at the job site or after the initial slump adjustment as permitted
    3
    above, whichever is later. The first and last quarter m discharged are exempt from this
    requirement. If the user is unprepared for discharge of the concrete from the vehicle, the
    producer shall not be responsible for the limitation of minimum slump after 30 min have
    elapsed starting either on arrival of the vehicle at the prescribed destination or at the
    requested delivery time, whichever is later.

    7 When air-entrained concrete is desired the purchaser shall specify the total air content of the
    concrete. The air content of air-entrained concrete when sampled from the transportation unit
    at the point of discharge shall be within a tolerance of +1.5% of the specified value.
    QCS 2014 Section 05: Concrete Page 28
    Part 06: Property Requirements

    8 Concrete strength test:

    (a) Each concrete strength sample shall consist of at least seven specimens, two to be
    tested at 7 days, three at 28 days and two to be tested at the discretion of the
    Engineer. Additional samples may be prepared as directed by the Engineer to be
    tested at the discretion of the Engineer for strength and/or durability.
    (b) When concrete cylinders have been specified, the concrete specimens shall not be
    capped using sulphur for environmental effect. The Contractor shall follow one of the
    following procedures and as approved by the Engineer:
    (i) Cap the specimens in accordance with ASTM C617 using neat cement paste
    and/or High-strength gypsum cement paste
    (ii) Saw cut and Grind the surface of the concrete to the desired planeness and
    perpendicular
    (iii) Test the concrete cylinders using Unbonded Caps in accordance with ASTM
    C1231

    l .
    .l.
    (iv) For field specimens, the contractor has the right to either use the conversion
    listed in EN 206 or determine the conversion factor for each specified concrete

    rw
    mix design by testing at least 36 comparative specimens (i.e. 18 cubes versus
    18 cylinders sampled from 3 consecutive batch trial mix).
    (c)
    (d) ta
    A minimum of one sample shall be taken of each mix every day the mix is used
    Samples shall be taken at the average rate of the followings:
    qa
    3
    (i) One sample every 30 m3, if the pour is less than or equal to 90 m
    3
    (ii) One sample every 100 m3, if the pour is greater than 90m and equal to or less
    as

    than 2000 m3,


    3
    (iii) One sample every 200 m3, if the pour exceeds 2000 m .
    se

    (e) Test specimens for compressive strength testing shall be prepared and cured in
    er

    accordance with BS EN 12390-2. The compressive strength of the specimens shall be


    determined in accordance with BS EN 12390-3.
    ov

    (f) A test shall be the average of the strength of the specimens tested at the age
    specified. If a specimen shows definite evidence other than low strength, of improper
    o

    sampling, moulding, handling, curing, or testing, it shall be discarded and the strength
    it

    of the remaining cubes shall then be considered the test result.


    et

    (g) Identity criteria of concrete strength shall be assessed for each individual test result
    m

    and the average of non-overlapping results as per BS EN 206-1 and explained below:
    (i) The average strength tests (average of two specimens or more) shall be equal
    to or greater than the characteristic (fck) + 2 MPa, and
    (ii) Any individual test result shall be equal to or greater than fck 4 MPa. The test
    result shall be that obtained from the average of the results of two or more
    specimens made from one sample for testing at the same age.

    9 If works test specimens fail at 28 days the Contractor shall suspend concreting operations
    and shall not proceed further without approval. The Contractor shall carry out in-situ testing
    of the suspect concrete in accordance with Part 13 of this Section, in the presence of the
    Engineer. All defective work shall be replaced and retested to the satisfaction of the
    Engineer.
    QCS 2014 Section 05: Concrete Page 29
    Part 06: Property Requirements

    6.8.3 Hardened Tests for Fiber-Reinforced Concrete

    (a) When post-crack flexural performance is used as the basis for acceptance of fiber-
    reinforced concrete, make, condition, and test sets of test specimens in accordance
    with Test Method ASTM C1399, C1550 or C1609/C1609M as specified.
    (b) When flexural strength is used as the basis for acceptance, make and test sets of at
    least three test specimens in accordance with the requirements for sampling and
    conditioning given in Test Method ASTM C1609/C1609M. Test specimens
    representing thin sections, as defined in C1609/C1609M, or specimens representing
    fiber-reinforced shotcrete of any thickness, shall be tested as cast or placed without
    being turned on their sides before placement on the support system. Acceptance shall
    not be based on flexural strength alone when post-crack performance is important.
    Test Method C1609/C1609M provides for the determination of first peak flexural
    strength when required by the purchaser. For many type-amount fiber combinations,

    .
    the first peak flexural strength is not significantly greater than the peak strength in

    l
    .l.
    flexure.

    rw
    (c) When compressive strength is used as part of the basis for acceptance of fiber-
    reinforced concrete, make sets of at least two test specimens in accordance with the
    applicable requirements of Practices ASTM C31/C31M and C192/C192M and as

    ta
    specified in this section, or Test Methods C42/C42M or C1604/C1604M and condition
    and test in accordance with Test Methods BS EN 12390, C39/C39M, C42/ C42M, or
    qa
    C1604/C1604M. Acceptance shall not be based on compressive strength alone.
    (d) The frequency of tests on hardened fiber-reinforced concrete shall be in accordance
    as

    with the following requirements:


    se

    (i) Batch-Mixing: Tests shall be made with same frequency as in conventional


    concrete. Each test shall be made from a separate batch. On each day fiber-
    er

    reinforced concrete is mixed, at least one test shall be made for each class of
    material.
    ov

    (ii) When fibers are added, subject for approval of the Engineer, at the truck mixer
    3
    the tests shall be made for each 20 m or fraction thereof, or whenever
    o

    significant changes have been made in the proportioning controls. On each day
    it

    fiber-reinforced concrete is mixed, at least one test shall be made for each class
    et

    of material.
    3
    m

    (iii) For Shotcrete: Tests shall be made for each 38 m placed using specimens
    sawed or cored from the structure or from corresponding test panels prepared in
    accordance with Practice ASTM C1604 and C 1140. On each day fiber-
    reinforced shotcrete is prepared; at least one test shall be made for each class
    of material.

    6.8.4 Quality Control charts

    1 The Contractor shall submit a continuous statistical analysis, on a monthly basis, for strength
    showing the potential strength of the concrete, variations in measured strength by
    determining the standard deviation (margin), batch-to-batch variations of the proportions and
    characteristics of the constituent materials in the concrete, the production, delivery, and
    handling process, and climatic conditions; and variations in the sampling, specimen
    preparation, curing, and testing procedures (within-test).
    QCS 2014 Section 05: Concrete Page 30
    Part 06: Property Requirements

    2 The Contractor shall provide in his analysis the mean strength, calculated standard deviation,
    the normal distribution of concrete strength and the frequency histogram. The Contractor
    shall draw the upper and lower lines for warning line (Target mean strength + 2 x standard
    deviation) and control line (Target mean strength + 3 x standard deviation)

    3 The contractor shall use the methods, of computing standard deviation along with coefficient
    of variation and factors for computing within-test standard deviation from range, addressed in
    ACI 214

    4 This recalculated margin, if adopted by the Engineer, becomes the current margin for the
    judgement of compliance with the specified characteristic strength of concrete

    6.9 WORKS TEST CUBES

    1 Test cubes shall be taken as specified from fresh mixed concrete which is being used in the

    l .
    Works and which has been prepared in the normal way.

    .l.
    rw
    2 Cubes shall be numbered sequentially and marked:

    (a) Time, date and name of individual


    (b) Section of work from which samples are taken
    ta
    qa
    (c) Mix reference and delivery note number
    (d) Name of technician
    as

    (e) and any other relevant information.


    se

    3 Tests for slump, as per BS EN 12350-2, and temperature shall be made and recorded
    whenever samples are taken.
    er

    4 The cube manufacture shall be in accordance with BS EN 12390-2.


    ov

    5 When Self Compacting Concrete is used, the concrete specimens shall not be consolidated
    o

    in moulds and it shall be placed in a single lift then levelled with minimum manipulation.
    it

    6 All samples shall be moulded at jobsite on a levelled surface area to within 20 mm per meter
    et
    m

    7 Immediately after moulding and finishing, the specimens shall be stored for a period up to 48

    h in a temperature range from 20 to 26 C and in an environment preventing moisture loss
    from the specimens

    8 Specimens shall not be transported or handled until at least 14 h after casting

    9 Transportation time from site to laboratory for final curing and strength testing shall not
    exceed 4 hours. Specimens shall be protected from direct sun or rapid evaporation and
    placed on cushion layer to reduce vibration

    6.10 REJECTION OF CONCRETE MIXES

    6.10.1 Rejection of Concrete Mixes:

    1 Concrete mixes shall be rejected if they fail to meet one or more requirements, which cannot
    be brought into compliance as related to any of the following:
    QCS 2014 Section 05: Concrete Page 31
    Part 06: Property Requirements

    (a) Improper class or grade of concrete


    (b) Slump or temperature not within specified limits
    (c) Oversized aggregate
    (d) Maximum water-cementitious ratio is exceeded

    2 Concrete shall not be rejected unless it has been visually inspected by the Engineer or
    representatives.

    6.10.2 Unsatisfactory Concrete Works

    1 A test shall be the average of the strengths of the specimens tested at the age specified. If a
    specimen shows definite evidence other than low strength, of improper sampling, moulding,
    handling, curing, or testing, it shall be discarded and the strength of the remaining specimens
    shall then be considered the test result and where the range of the test values is more than

    l .
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    15 % of the mean, the results shall be disregarded unless an investigation reveals an
    acceptable reason to justify disregarding an individual test value. To conform to the

    rw
    requirements of this specification, strength tests representing each class of concrete must
    meet the following requirements:

    (a)
    ta
    The average of any three consecutive strength tests shall be equal to, or greater than,
    the specified strength, f c, and
    qa
    (b) When the specified strength is 35 MPa or less, no individual strength test (average of
    at least two specimen tests) shall be more than 3.5 MPa below the specified strength, f
    as

    c
    se

    (c) When the specified strength is greater than 35 MPa, no individual strength test
    (average of two specimen tests) shall be less than 0.90 f c.
    er

    2 Should any of the test results be unsatisfactory, the Engineer may order the work to be
    ov

    stopped pending his further instructions. Executed work for which test results are
    unsatisfactory shall be liable to rejection and if so advised the work shall be rebuilt at the
    Contractor's expense.
    it o

    3 In the case of the 7-day works cube tests proving unsatisfactory, the work may be stopped
    et

    liable to rejection pending the result of the 28-day test. If the test results fail to comply with
    the requirements, the work represented shall be immediately liable to rejection.
    m

    4 The cost of all such cuttings, preparation of specimens, transportation and testing, and of
    making good the portions of the structure affected shall be borne by the Contractor.

    5 Regardless of satisfactory test cube results, any concrete work which, in the Engineer's
    opinion, is excessively honeycombed or in any other way is defective, shall be liable to
    rejection. Minor defects apparent on stripping the formwork must be made good at the
    Contractor's expense. No such repair work shall be carried out until after inspection by the
    Engineer and his acceptance of the proposed treatment has been given. Work which has
    not been previously inspected but which shows signs of such treatment shall be liable to
    rejection as defective work.

    6 The cost of all delays on site due to faulty concrete work shall be met by the Contractor.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 07: Concrete Plants

    7 CONCRETE PLANTS.............................................................................................. 2
    7.1 GENERAL ............................................................................................................... 2
    7.1.1 Scope 2
    7.1.2 References 2
    7.2 BATCHING .............................................................................................................. 3
    7.2.1 General 3
    7.2.2 Plant Type 5
    7.2.3 Bins and Weight Batchers 5
    7.2.4 Tolerances of Measuring Equipment 5
    7.2.5 Batching Tolerances 6
    7.2.6 Charging the Mixer 7
    7.3 MIXING.................................................................................................................... 7

    .
    7.3.1 Charging Concrete Materials 7

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    .l.
    7.3.2 Mixing Time for Stationary Mixers 7

    rw
    7.3.3 Mixing 8
    7.3.4 Limitation of Water : Cement Ratio 8
    7.4
    7.4.1 General ta
    READY-MIXED CONCRETE ................................................................................... 9
    9
    qa
    7.5 APPENDIX A: CONCRETE PLANT INSPECTION CHECKLIST ........................ 11
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    QCS 2014 Section 05: Concrete Page 2
    Part 07: Concrete Plants

    7 CONCRETE PLANTS

    7.1 GENERAL

    7.1.1 Scope

    1 This Part covers batching and mixing of concrete together with inspection of concrete plants.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 ............... General
    Part 2 ............... Aggregates
    Part 3 ............... Cementitious materials

    l.
    Part 4 ............... Water

    .l.
    Part 5 ............... Admixtures

    rw
    Part 6 ............... Property Requirements
    Part 8 ............... Transporting and Placing of Concrete
    Part 15 ............. Hot Weather Concreting
    Part 16 ............. Miscellaneous
    ta
    qa
    7.1.2 References
    ACI 304 ......................Guides for Measuring, Mixing, Transporting, and Placing Concrete
    as

    ASTM C94 ..................Specification for ready-mixed concrete


    se

    BS 1881......................Testing concrete
    er

    BS 8500......................Concrete Specification complementary to EN 206


    ov

    BS EN 12390..............Testing of hardened concrete


    BS EN 12390-1:2000 .Testing hardened concrete Part 1: Shape, dimensions and other
    o

    requirements for specimens and moulds


    it

    BS EN 12390-2:2000 .Testing hardened concrete Part 2: Making and curing specimens


    et

    for strength tests


    m

    BS EN 12390-3:2000 .Testing hardened concrete Part 3: Compressive strength of test


    specimens
    BS EN 12390-4:2000 .Testing hardened concrete Part 4: Compressive strength -
    Specification for testing machines
    BS EN 12390-5:2000 .Testing hardened concrete Part 5: Flexural strength of test
    specimens
    BS EN 12390-6:2000 .Testing hardened concrete Part 6: Tensile splitting strength of test
    specimens
    BS EN 12390-7:2000 .Testing hardened concrete Part 7: Density of hardened concrete
    BS EN 12390-8:2000 .Testing hardened concrete Part 8: Depth of penetration of water
    under pressure

    BS EN 12350..............Testing fresh concrete


    BS EN 12350-1:2000 .Testing fresh concrete - Part 1: Sampling
    QCS 2014 Section 05: Concrete Page 3
    Part 07: Concrete Plants

    BS EN 12350-2:2000 .Testing fresh concrete - Part 2: Slump test


    BS EN 12350-3:2000 .Testing fresh concrete - Part 3: Vebe test
    BS EN 12350-4:2000 Testing fresh concrete - Part 4: Degree of compatibility
    BS EN 12350-5:2000 Testing fresh concrete - Part 5: Flow table test
    BS EN 12350-6:2000 Testing fresh concrete - Part 6: Density
    BS EN 12350-7:2000 Testing fresh concrete - Part 7: Air content - Pressure methods

    GSO EN 206-1, ..........Concrete. Specification, performance, production and conformity


    GSO ISO 1920-1 ........Testing of concrete Part 1: Sampling of fresh concrete
    GSO ISO 1920-2 ........Testing of concrete part 2: properties of fresh concrete
    GSO ISO 1920-3 ........Testing of concrete part 3: Making and curing test specimens.
    GSO ISO 1920-4 ........Testing of concrete part 4: strength of hardened concrete.

    l .
    GSO ISO 1920-5 ........Testing of concrete part 5: properties hardened concrete other than

    .l.
    strength.

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    GSO ISO 1920-6 ........Testing of concrete part 6: sampling, preparing and testing of
    concrete core.

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    GSO ISO 1920-7 ........Testing of concrete part 7: Nondestructive test on hardened
    concrete.
    qa
    ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of
    concrete for samples prepared in the field or in the laboratory
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    ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete


    cylinders in compression
    se

    ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of


    elasticity in compression
    er

    7.2 BATCHING
    ov

    7.2.1 General
    o

    1 During measurement operations, aggregates shall be handled in a manner to maintain their


    it

    desired grading, and all materials shall be weighed to the tolerances required for the desired
    et

    reproducibility of the selected concrete mix.


    m

    2 The coarse aggregate shall be controlled to minimize segregation and undersized material.
    Fine aggregate shall be controlled to minimize variations in gradation, giving special attention
    to keeping finer fractions uniform and exercising care to avoid excessive removal of fines
    during processing

    3 Avoid blending two sizes of fine aggregate by placing alternate amounts in bins or stockpiles
    or when loading cars or trucks. Satisfactory results are achieved when different size fractions
    are blended as they flow into a stream from regulating gates or feeders. A more reliable
    method of control for a wide range of plant and job conditions, however, is to separate
    storage, handling, and batching of the coarse and fine fractions
    QCS 2014 Section 05: Concrete Page 4
    Part 07: Concrete Plants

    4 Stockpiling of coarse aggregate shall be kept to a minimum because fines tend to settle and
    accumulate. When stockpiling is necessary use of correct methods minimizes problems with
    fines, segregation, aggregate breakage, excessive variation in gradation, and contamination.
    Stockpiles shall be built up in horizontal or gently sloping layers, not by end-dumping. Trucks,
    loaders, and dozers, or other equipment shall not be operated on the stockpiles because, in
    addition to breaking the aggregate, they frequently track dirt onto the piles

    5 Stockpiles located to prevent contamination; arranged to assure that each aggregate as


    removed from its stockpile is distinct and not intermingled with others. The concrete supplier
    is asked to separate storage bins or compartments for each size and type of aggregate
    properly constructed and charged to prevent mixing of different sizes or types

    6 Sequencing and blending of the ingredients during charging of the mixers shall be carried out
    in such a way as to obtain uniformity and homogeneity in the concrete produced as indicated
    by such physical properties as unit weight, slump, air content, strength and air-free mortar

    l .
    content in successive batches of the same mix proportions and as stated in ASTM C94

    .l.
    Annex A.

    rw
    7 The mix recipe for the mixes to be produced shall be readily available to the mixer operator.
    Only authorised personnel shall be allowed to make changes to the mix design.

    ta
    qa
    8 All cement bags shall be stored in weathertight, properly ventilated structures to prevent
    absorption of moisture.
    as

    9 Storage facilities for bulk cement shall include separate compartments for each type of
    cement used. The interior of a cement silo shall be smooth, with a minimum bottom slope of
    se

    50 degrees from the horizontal for a circular silo and 55 to 60 degrees for a rectangular silo.
    Silos shall be equipped with non-clogging air-diffuser flow pads through which small
    er

    quantities of dry, oil-free, low-pressure air can be introduced intermittently at approximately 3


    to 5 psi (20 to 35 kPa) to loosen cement that has settled tightly in the silos. Storage silos shall
    ov

    be drawn down frequently, preferably once per month, to prevent cement caking.

    10 Each bin compartment from which cement is batched shall include a separate gate, screw
    o

    conveyor, air slide, rotary feeder, or other conveyance that effectively allows both constant
    it

    flow and precise cutoff to obtain accurate batching of cement


    et

    11 Fly ash, ground slag, or other pozzolans shall be handled, conveyed, and stored in the same
    m

    manner as cement. The bins, however, shall be completely separate from cement bins
    without common walls that could allow the material to leak into the cement bin.

    12 All bins and silos shall be properly tagged at silos, bins and near charging hose.

    13 Bags of cement should be stacked on pallets or similar platforms to permit proper circulation
    of air. For a storage period of less than 60 days, stack the bags no higher than 14 layers, and
    for longer periods, no higher than seven layers.

    14 The water batcher and the water pipes should be leak-free. If ice is used, the ice facilities,
    including the equipment for batching and transporting to the mixer, should be properly
    insulated to prevent the ice from melting before it is in the mixer.
    QCS 2014 Section 05: Concrete Page 5
    Part 07: Concrete Plants

    7.2.2 Plant Type

    1 Manual control batching. Manual plants are acceptable for small jobs having low batching
    3 3
    rate requirements, generally for jobs up to a total concrete quantity of 1000 m and 10 m /h.

    2 Semi-automatic control batching. In this system, aggregate bin gates for charging batchers
    are opened by manually operated push buttons or switches. Gates are closed automatically
    when the designated weight of material has been delivered.

    3 Automatic control batching. Automatic batching of all materials is electrically activated by a


    single starter switch. However, interlocks shall interrupt the batching cycle when the scale
    has not returned to 0.3 % of zero balance or when weighing tolerances detailed in
    Clause 7.2.5 of this Part are exceeded.

    7.2.3 Bins and Weight Batchers

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    .l.
    1 Batch plant bins shall be of sufficient size to effectively accommodate the production capacity

    rw
    of the plant. Compartments in bins separate the various concrete materials, and the shape
    and arrangement of aggregate bins shall prevent aggregate segregation and leakage.

    2
    ta
    Weight batchers shall be charged with easy-operating clam shells or undercut radial-type bin
    qa
    gates.

    3 Gates used to charge semi-automatic and fully automatic batchers shall be power operated
    as

    and equipped with a suitable in flight correction to obtain the desired weighing accuracy. They
    shall be calibrated by the plant supplier for the types of aggregate used at the standard range
    se

    of moisture contents.
    er

    4 Weigh batchers shall be accessible for obtaining representative samples, and they shall be
    arranged to obtain the proper sequencing and blending of aggregates during charging of the
    ov

    mixer.

    5 The amount of concrete mixed in any one batch shall not exceed the rated capacity of the
    o

    mixer.
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    et

    6 All mixing and batching plants shall be maintained free of set concrete or cement and shall
    be clean before commencing mixing.
    m

    7 For each different type of cement at use at the plant a separate silo shall be provided.

    7.2.4 Tolerances of Measuring Equipment

    1 Scales for weighing concrete ingredients shall be accurate when in use within 3 % and
    1.5 % for additives. Standard test weights shall be available to permit the checking of scale
    accuracy.

    2 Testing of the weighers shall be at three-month intervals. If water is dispensed by flow meter
    the frequency of testing shall be at three-month intervals. Such testing shall be undertaken by
    a calibration company approved by the Central Materials Laboratory, and calibrated to
    recognized international standards.

    3 Test certificates shall be displayed in the plant in prominent positions.


    QCS 2014 Section 05: Concrete Page 6
    Part 07: Concrete Plants

    7.2.5 Batching Tolerances

    1 Operation of batching equipment shall be such that the concrete ingredients are consistently
    measured within the following tolerances. The plant shall have the ability to flag values that
    are outside these limits. The operator shall make manual adjustments to the batching and
    the final weights shall be within the given limits stated in table 7.1. Any adjustments shall be
    displayed on the batch weight printouts.

    2 Cementitious materials shall be measured by mass. When supplementary cementitious


    materials are used in the concrete mixtures, the cumulative mass is permitted to be
    measured with hydraulic cement, but in a batch hopper and on a scale which is separate and
    distinct from those used for other materials.

    3 Aggregate shall be measured by mass. Batch mass measurements shall be based on dry
    materials and shall be the required masses of dry materials plus the total mass of moisture

    l .
    (both absorbed and surface) contained in the aggregate

    .l.
    rw
    4 Mixing water shall consist of water added to the batch, ice added to the batch, water
    occurring as surface moisture on the aggregates, and water introduced in the form of
    admixtures. The added water shall be measured by weight or volume.

    5 ta
    Added ice shall be measured by weight. In the case of truck mixers, any wash water retained
    qa
    in the drum for use in the next batch of concrete shall be accurately measured; if this proves
    impractical or impossible the wash water shall be discharged prior to loading the next batch
    as

    of concrete
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    6 Chemical admixtures in powdered form shall be measured by mass. Liquid chemical


    admixtures shall be batched by mass or volume
    er

    Table 7.1
    Typical batching tolerances Ingredient
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    Batch weights greater than Batch weights less than


    Typical batching
    30% of scale capacity 30% of scale capacity
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    tolerances
    Ingredient Individual Cumulative Individual Cumulative
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    batching batching batching batching


    et

    Cement and other 1% of required mass or


    Not less than required weight or 4%
    m

    cementitious 0.3% of scale capacity,


    more than required weight
    Materials whichever is greater

    Water (by volume or Not


    1 1 Not recommended
    weight), % recommended

    0.3% of scale
    capacity or
    3% of required
    Aggregates, % 2 1 2
    cumulative
    Weight, whichever is
    less
    Admixtures (by Not
    3 3 Not recommended
    volume or weight), % recommended
    QCS 2014 Section 05: Concrete Page 7
    Part 07: Concrete Plants

    7 Cement supplied in bags shall be placed directly from the bag into the intake of the mixing
    plant and each batch must contain one or more complete bags of cement. No mixer having
    a rated capacity of less than a one-bag batch shall be used and the mixer shall not be
    charged in excess of its rated capacity.

    7.2.6 Charging the Mixer

    1 Each batch shall be so charged into the mixer that some of the water will enter in advance of
    the cement and aggregates. Controls shall be provided to prevent batched ingredients from
    entering the mixer before the previous batch has been completely discharged.

    2 The first batch of concrete through the mixer shall contain an excess of cement to allow for
    coating of the inside of the mixing drum without reducing the required mortar content of the
    mix.

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    3 Mixing plant that has been out of action for more than 30 minutes shall be thoroughly cleaned

    .l.
    before any fresh concrete is mixed in it.

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    4 When a change of mix is made to one using a different type of cement, the mixing plant shall
    be thoroughly cleaned of all traces of the previously used cement, whatever is the time
    interval between successive mixes.
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    7.3 MIXING
    as

    7.3.1 Charging Concrete Materials


    se

    1 Water shall enter the mixer first with continuous flow while other ingredients are entering the
    mixer. Water charging pipes must be of the proper design and of sufficient size so that water
    er

    enters at a point well inside the mixer and charging is completed within the first 25% of the
    prescribed mixing time and where concrete uniformity shall be verified by approved inspector.
    ov

    2 Admixtures shall be charged to the mixer in accordance with the instructions of the
    manufacturer. Automatic dispensers shall be used.
    it o

    7.3.2 Mixing Time for Stationary Mixers


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    1 The mixing time required shall be based upon the ability of the mixer to produce uniform,
    homogeneous, consistent mixture throughout the batch and from batch to batch.

    2 Final mixing times shall be based on the results of mixer performance tests made at the start
    of the project and the time fixed unless a change is authorised by the Engineer. The time
    shall however not be less than 60 Sec unless otherwise verified as stated hereafter. Where
    no mixer performance tests are made, the acceptable mixing time for mixers having
    3
    capacities of 0.75 m or less shall be not less than 1 min. For mixers of greater capacity, this
    minimum shall be increased 15 s for each cubic meter or fraction thereof of additional
    capacity.
    QCS 2014 Section 05: Concrete Page 8
    Part 07: Concrete Plants

    3 Where mixer performance tests have been made on given concrete mixtures in accordance
    with the testing program ASTM C94 Annex A and NRMCA certification, and the mixers have
    been charged to their rated capacity, the acceptable mixing time is permitted to be reduced
    for those particular circumstances to a point at which satisfactory mixing defined in ASTM
    C94 and NRMCA certification for central mixing plants shall have been accomplished. When
    the mixing time is so reduced the maximum time of mixing shall not exceed this reduced time
    by more than 60 s for air-entrained concrete. The mixing time shall be measured from the
    time all ingredients are in the mixer.

    4 Batch mixers with audible indicators used in combination with interlocks which prevent mixer
    discharge prior to completion of a preset mixing time shall be provided on automatic plants
    and are also desirable on manual plants.

    5 The mixer shall be designed for starting and stopping under full load.

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    7.3.3 Mixing

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    1 All structural concrete to be placed in-situ shall be manufactured in a computer controlled
    batching plant of the types described in Clause 7.2.2 of this Part.

    2
    ta
    The plant shall be complete with suitable water chilling or ice making facilities, or both, to
    ensure concrete temperatures are maintained as specified in Parts 6 and 15 of this Section.
    qa
    3 Concrete shall be mixed in batches in plant capable of combining the aggregates, cement
    as

    and water (including admixtures, if any) into a mixture of uniform colour and consistency and
    of discharging the mixture without segregation.
    se

    4 Automatic moisture content probes, set in the hoppers shall be used to continuously
    er

    determine the moisture content of the aggregates.


    ov

    5 Contractor shall make due allowance for the water contained in the aggregates when
    determining the quantity of water to be added to each mix.
    o

    6 The amount of water added to each mix shall be adjusted to maintain the constant approved
    it

    water : cement ratio of the mixed concrete.


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    7.3.4 Limitation of Water : Cement Ratio


    m

    1 No concrete shall exceed the water : cement ratio as given in Part 6 of this Section.

    2 The quantity of water used in mixing shall be the least amount that will produce a workable
    homogeneous plastic mixture which can be worked into the forms and around the
    reinforcement.

    3 Excess water over the maximum allowed by the mix design shall not be permitted and any
    batch containing such excess will be rejected.
    QCS 2014 Section 05: Concrete Page 9
    Part 07: Concrete Plants

    7.4 READY-MIXED CONCRETE

    7.4.1 General

    1 The manufacture of readymix concrete for use in government projects may only be carried
    out in batching plants that have an approval certificate issued by the Central Materials
    Laboratory. When this certificate is under renewal process by the readymix concrete
    manufacturer, other certificate such as NRMCA shall be considered by the Engineer as
    approval on the uniformity and consistency of the facility. The engineer may request to re-
    validate the uniformity tests under his supervision. In addition, the use of readymix concrete
    in any part of the work shall require the Engineers written approval.

    2 The Contractor shall satisfy the Engineer on the following:

    (a) materials used in ready-mixed concrete comply with the specification in all respects

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    (b) manufacturing and delivery resources of the proposed supplier are adequate to ensure
    proper and timely completion.

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    3 The specified requirements as to the sampling, trial mixing, testing and quality of concrete, of
    various grades as described in Part 6 of this Section, shall apply equally to ready-mixed
    concrete.
    ta
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    4 Every additional facility, including but not limited to testing equipment, labour, laboratory
    facilities and transport, which the Engineer or persons authorised by him may require for the
    as

    supervision and inspection of the batching, mixing, testing and transporting to Site of ready-
    mixed concrete shall be provided by the Contractor at no extra cost.
    se

    5 Copies of all delivery notes shall be submitted to the Engineer in duplicate, on computer
    er

    generated forms and shall include at least the following information.


    ov

    (a) name of supplier, serial number of ticket and date


    (b) truck number
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    (c) name of Contractor


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    (d) name of Contract and location of office


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    (e) grade of concrete


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    (f) specified workability


    (g) type and source of cement
    (h) source of aggregate
    (i) nominal maximum size of aggregate
    (j) quantity of each concrete ingredient
    (k) type of admixture and quantity
    (l) water content
    (m) time of loading and departure from ready-mix plant
    (n) arrival and departure times of truck
    (o) time of completion of discharge
    QCS 2014 Section 05: Concrete Page 10
    Part 07: Concrete Plants

    (p) notations to indicate equipment was checked and found to be free of contaminants
    prior to batching.

    6 A copy of the delivery note shall be given to the Engineer's site representative for each load.

    7 Unless approved otherwise in advance of batching all concrete of single design mix for any
    one day's pour shall be from a single batch plant of a single supplier.

    8 Ready-mix concrete shall conform to BS 8500 in addition to GSO EN 206-1, except


    materials, testing and mix design shall be as specified in this Section.

    9 Transit mixers equipped with automatic devices for recording the number of revolutions of
    the drum shall be used.

    10 Excess water over the maximum allowed by the mix design shall not be added.

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    11 Each mixer truck shall arrive at the job site with its water container full.

    rw
    12 In the event that a container is not full or concrete tests give a greater slump than acceptable,
    the load shall be rejected.

    13 ta
    Shade temperature and concrete temperature shall be recorded at the point of discharge of
    qa
    the mixer and at placement for each load of concrete delivered to site.

    14 Maximum and minimum temperatures and wet bulb temperatures shall be recorded daily.
    as

    15 Slump tests shall be performed in accordance with BS EN 12350 or relevant GSO standard
    se

    at the point of placement as stated in Part 6.


    er

    16 No water shall be added at the Site.


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    END OF PART
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    QCS 2014 Section 05: Concrete Page 11
    Part 07: Concrete Plants

    7.5 APPENDIX A: CONCRETE PLANT INSPECTION CHECKLIST

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    Qatar General Organization for Standards and Standardization

    CONCRETE PLANT INSPECTION CHECK LIST

    New Approval Renewal Regular Inspection

    1.0 GENERAL INFORMATION OF PLANT


    1.1 Company Name :
    1.2 Inspection Date : AM / PM

    1.3 Plant Location :

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    1.4 Plant No/s :

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    1.5 Plant Manufacturer :
    1.6 Plant ID No. :
    1.7 Approval Certificate No : ta
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    1.8 Contact a Plant :
    as

    2.0 FACTORY CONDITION


    2.1 Concrete Floor Under Mixer and silos Yes No
    se

    2.2 Concrete floor with Slope under materials Yes No


    er

    2.3 Hard and stable surface for Access and ramps Yes No
    ov

    2.4 Floors Clean Yes No

    2.5 Cleaning plan implements Yes No


    ito

    2.6 Drainage System Yes No


    et

    2.7 Separated Place of Waste materials Yes No


    m

    2.8 Separated Place of wash tank Yes No

    3.0 MATERIAL STORAGE AND HANDLING


    3.1 Cement and Cementations materials (including blended cements, fly ash, GGBS, silica fume..)

    3.1.1 The Silos of Cement

    A. Outside Cleaning for Cement silo Yes No

    B. Cement scale calibration Current Expired

    C. Reflective color for cement silo Yes No

    D. Board clarify the cement type Yes No

    3.1.2 The silos of cementations materials


    A. Outside Cleaning for Cementations silo Yes No

    Page 12 of 15
    B. Cementations scale calibration Current Expired

    C. Reflective Color for Cementations Silo Yes No

    D. Board Clarify the Cementations Type Yes No


    E. All Cementations Materials Excess of use
    Yes No
    protected under shad

    3.2 Aggregates:
    A. Aggregate Shading Yes No

    B. Aggregate Separation under shad Yes No

    C. Aggregate Separation in bins Yes No

    .
    D. Aggregate scale calibration Current Expired

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    .l.
    E. Cover for Conveyer Belts Yes No

    rw
    F. Board Clarify the Aggregate Type Yes No
    G. Effective method for checking the level of
    No
    material inside the bins
    Yes
    ta
    qa
    4.0 Water & Admixture Supply
    4.1 Water supply
    as

    A. Water pipe insulated Yes No


    se

    B. Chiller using Yes No


    er

    C. Ice plant or Nitrogen cooling Yes No


    ov

    D. Water gauge calibration Current Expired

    4.2 Admixture supply


    ito

    A. Additive storage silos Yes No


    et

    B. Additive Gage calibration Current Expired


    m

    C. Board Clarify the Admixture Type Yes No


    D. All admixture excess of use protected under
    Yes No
    shad
    E. Agitation system for all storage tanks or silos
    Yes No
    more than 5000 liter

    5.0 Requirements of the Concrete batching plant


    5.1 Certificate validity Yes No

    5.2 Computer controlled Yes No

    5.3 Plant type Wet mix Dry mix

    5.4 Computer printout Yes No

    5.5 Calibration validity Current Expired

    5.6 Cleaning of plant blades Yes No

    Page 13 of 15
    6.0 Laboratory
    6.1 Records for raw materials and cube tests

    Frequency
    Was Test of Tests
    Required Tests to QCS 2014 Comments of Inspection
    Performed?
    D W M
    6.1.1 Grading Yes No

    6.1.2 Fines content (%) Yes No

    6.1.3 Fines quality Yes No

    6.1.4 Clay lumps and friable


    Yes No
    particles

    .
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    6.1.5 Lightweight pieces Yes No

    rw
    6.1.6 Organic impurities Yes No

    6.1.7 Water Absorption Yes No

    6.1.8 Particle density Yes No ta


    qa
    6.1.9 Shell Content Yes No
    as

    6.1.10 Flakiness Index (%) Yes No

    6.1.11 Chloride content (%) Yes No


    se

    6.1.12 Sulphate content (%) Yes No


    er

    6.1.13 Soundness (%) Yes No


    ov

    6.1.14 Los Angeles abrasion Yes No

    6.1.15 Moisture Content (%) Yes No


    ito

    6.1.16 Compressive Strength Yes No


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    6.1.17 Other test*


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    *Such as recycled aggregate

    6.2 Specimens testing at inspection time


    ITEMS CASE COMMENTS
    6.2.1 Method of slump test Yes No

    6.2.2 Curing of samples Yes No

    6.2.3 Water Temperature Of Curing Tank Yes No

    6.2.4 Concrete Temperature at plant Yes No

    6.2.5 Concrete Slump at plant Yes No

    Page 14 of 15
    6.3 Laboratory equipment calibration
    EQUIPMENT CASE COMMENTS
    6.3.1 Compression Testing Machine Yes No

    6.3.2 Sieves Yes No

    6.3.3 Balance Yes No

    6.3.4 Thermometers Yes No

    7.0 Recommendations

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    8.0 Plant representative information


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    Name of representative :
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    Contract number :

    Signature :
    ito

    9.0 Inspector team


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    Inspected by Signature
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    Page 15 of 15
    QCS 2014 Section 05: Concrete Page 1
    Part 08: Transportation and Placing of Concrete

    8 TRANSPORTATION AND PLACING OF CONCRETE ............................................ 2


    8.1 GENERAL ............................................................................................................... 2
    8.1.1 Scope of Work 2
    8.1.2 References 2
    8.1.3 Submittals 2
    8.2 TRANSPORTATION ............................................................................................... 3
    8.2.1 General 3
    8.2.2 Pumped Concrete 3
    8.2.3 Records 4
    8.3 PLACING CONCRETE ............................................................................................ 4
    8.3.1 General 4
    8.3.2 Preparation 4

    .
    8.3.3 Placing 5

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    8.3.4 Compaction 7

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    8.3.5 Continuity of Concrete Work 8

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    QCS 2014 Section 05: Concrete Page 2
    Part 08: Transportation and Placing of Concrete

    8 TRANSPORTATION AND PLACING OF CONCRETE

    8.1 GENERAL

    8.1.1 Scope of Work

    1 This part deals with the transportation, placing and compaction of concrete.

    2 Related Parts are as follows:


    This Section
    Part 1 ............... General
    Part 7, .............. Concrete Plants
    Part 9, .............. Formwork

    .
    Part 15, ............ Hot Weather Concreting

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    Part 16, ............ Miscellaneous

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    8.1.2 References
    ACI 304, ............. Guide for Measuring, Mixing, Transporting, and Placing Concrete

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    ASTM C94, ......... Specification for ready-mixed concrete
    BS 8500,............. Concrete, Complementary British Standard to BS EN 206-1.
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    BS EN 206-1, ..... Concrete. Specification, performance, production and conformity
    EN 1992-1-1 ....... Eurocode 2: Design of concrete structures. General rules and rules for
    buildings
    as

    8.1.3 Submittals
    se

    1 Should the Contractor propose to use concrete pumps for the transportation and placing of
    er

    concrete, he shall submit details of the equipment and operating techniques he proposes to
    use for the approval of the Engineer.
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    2 A method statement shall be submitted for approval for major concrete placements, which
    shall address
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    (a) the planned rate of placing


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    (b) number of batching plants


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    (c) number of trucks


    (d) number and positioning of pumps
    (e) pour sequence
    (f) quality control measures
    (g) spare equipment
    (h) any other factors that might affect the placing of concrete.

    3 The method statement should be submitted at least three days in advance of the planned
    pour. If required by the Engineer or any other concerned party a prepour planning meeting
    may be arranged with representatives from the ready-mix supplier, Contractor and Engineer.

    4 The Contractor shall submit to the Engineer for approval details of his proposed operations
    and standby equipment.
    QCS 2014 Section 05: Concrete Page 3
    Part 08: Transportation and Placing of Concrete

    8.2 TRANSPORTATION

    8.2.1 General

    1 Transportation delivery and handling shall be in accordance with the requirements of BS


    8500 and BS EN 206-1.

    2 Concrete shall be conveyed from the mixer to its place in the Works as rapidly as possible by
    methods which will prevent segregation or drying out and ensure that the concrete is of the
    required workability at the point and time of placing.

    3 Should segregation occur in the concrete then the materials shall be remixed to the
    satisfaction of the Engineer or discarded. Furthermore the cause of the segregation shall be
    determined and further occurrences prevented.

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    4 The Contractor shall ensure that the time between placing of different lifts or layers of

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    concrete is short enough to prevent the formation of cold joints. The Contractor shall ensure

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    that there is a back up plant that can be used in the event of a breakdown, and that adequate
    provision has been made for the number of delivery trucks.

    5
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    The concrete shall be transported to the site in an approved type of truck mixer or agitator
    qa
    truck which apart from the cab and chassis shall be painted white and kept clean at all times.
    The discharge chute and other dirty areas shall be washed down after delivery to prevent
    spillage on the roads.
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    6 If a truck mixer or a truck body with an agitator is used for central-mixed concrete, limit the
    se

    volume of concrete charged into the truck to 80% of the drum or truck volume as per ASTM
    C94 and NRMCA requirements. if shrink mixing is approved by the engineer limit the volume
    er

    of concrete charged into the truck to 63% of the drum volume.


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    7 All trucks shall be rotated 30 revolutions at mixing speed before discharging concrete to
    assure uniformity.
    o

    8 The insides of concrete mix trucks shall be inspected periodically, and any build up of
    it

    concrete removed that may impair the efficiency of the mixing action. All trucks shall be
    et

    NRMCA certified or any equivalent certification


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    9 Discharge of the concrete shall be completed within 90 min, or before the drum has revolved
    300 revolutions, whichever comes first, after the introduction of the mixing water to the
    cement and aggregates or the introduction of the cement to the aggregates. These limitations
    are permitted to be waived by the purchaser if the concrete is of such slump or slump flow
    after the 90 min time or 300-revolution limit has been reached that it can be placed, without
    the addition of water, to the batch. In hot weather, or under conditions contributing to quick
    stiffening of the concrete, a time less than 90 min is permitted to be specified by the Engineer

    8.2.2 Pumped Concrete

    1 Access for the pump shall be checked prior to the pour. If access cannot be assured, the
    Contractor shall not continue with concreting operations.

    2 If approval is obtained for pumped concrete, the Contractor shall ensure that shock is not
    transferred from the pipeline to the formwork and previously laid concrete.
    QCS 2014 Section 05: Concrete Page 4
    Part 08: Transportation and Placing of Concrete

    3 During placing concrete by pumping the end hose must never reach into the concrete. All
    measures shall be taken to avoid blockage of the delivery hose system. The Compaction of
    concrete shall be carried out as per standard practice procedures.

    4 Grout shall be pumped through the concrete pump to provide initial lubrication. The initial
    discharge of any pumped concrete shall not be incorporated in the permanent works.

    5 Where concrete is conveyed by chuting or pumping the plant shall be of a size and design to
    ensure continuous flow in the chute or pipe. The slope of the chute or the pressure of the
    pump shall allow the concrete to flow without the use of any water additional to that approved
    by the Engineer to produce the required consistency and without segregation of the
    ingredients. The delivery end of the chute or pipe shall be thoroughly flushed with water
    before and after each working period and kept clean. The water used for this purpose shall
    be discharged outside and away from any permanent works.

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    8.2.3 Records

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    1 Within 24 h of delivery, the Contractor shall provide the Engineer with delivery notes giving
    the information required under Paragraph 7.4.1.5 of this Section.

    8.3 PLACING CONCRETE


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    8.3.1 General
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    1 The Contractor shall obtain the approval of the Engineer to his proposed arrangements
    before beginning concreting.
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    2 All placing and compacting of concrete shall be carried out under the direct supervision of a
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    competent member of the Contractors staff with a minimum of five years of experience in
    concreting works, and in a manner to produce a watertight concrete of maximum density and
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    strength.

    3 For night concreting operations, the Contractor shall arrange adequate suitable lighting.
    it o

    4 The Contractor shall provide safe secure access for all personnel on concreting operations.
    et
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    5 Where the thickness of the concrete section exceeds 600 mm the Contractor shall adopt
    special precautions, to be approved by the Engineer, to avoid thermal cracking due to
    external and core temperature differentials.

    6 Concrete shall not be placed in adverse weather conditions such as dust storms or heavy
    rain.

    8.3.2 Preparation

    1 No concrete shall be placed until the Engineer has inspected and approved in writing the
    surfaces upon which the concrete is to be placed, the formwork, and reinforcing steel. The
    Contractor shall give the Engineer at least 24 hours notice to enable this inspection to be
    carried out. If concrete is not placed within 24 hours of approval being given, approval shall
    be obtained again before concreting. An inspection shall be made immediately prior to
    concreting to check the cleanliness of the forms.
    QCS 2014 Section 05: Concrete Page 5
    Part 08: Transportation and Placing of Concrete

    2 Wood forms, unless lined, shall be oiled or wetted with water in advance of placing concrete
    so that joints will tighten and prevent seepage of cement grout from the mix.

    3 The reinforcement shall be sprayed with a small amount of water prior to starting the pour.
    Reinforcement shall be secured in position, inspected, and accepted by the Engineer before
    placing the concrete.

    4 All inserts, anchor bolts, sleeves and other embedded items shall be accurately located,
    using templates where appropriate, and held securely to prevent displacement during the
    placing of the concrete. Aluminium items shall be completely covered and protected when
    embedded in the concrete.

    5 Except where shown on the drawings, no fixtures shall be attached to the concrete by shot
    fixing or drilling without acceptance by the Engineer. Notwithstanding any such authorisation,
    the Contractor shall be responsible for all damage so caused to the concrete and make good

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    at his own expense.

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    6 Water shall be removed from excavations before concrete is deposited. Any flow of water
    shall be diverted through proper side drains and shall be removed without washing over
    freshly deposited concrete. All dewatering works shall be continued as long as required.

    ta
    Hardened concrete, debris, and foreign materials shall be removed from interior of forms and
    qa
    from inner surfaces of mixing and conveying equipment.

    7 Runways or other means accepted by the Engineer shall be provided for wheeled equipment
    as

    to convey the concrete to the points of deposit. Equipment used to deposit concrete shall not
    be wheeled over reinforcement nor shall runways be supported on reinforcement.
    se

    8 Before depositing new concrete on or against concrete that has set, existing surfaces shall
    er

    be thoroughly roughened and cleaned of laitance, foreign matter and loose particles. Forms
    shall be re-tightened and existing surfaces slushed with a grout coat of mortar consisting of
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    cement and fine aggregate in the same proportion in the mix, but not leaner than one (1) part
    cement to two (2) parts fine aggregate, after the existing surface has been moistened. New
    concrete shall be placed before the grout has attained initial set. Horizontal construction
    o

    joints shall be given a brush coat of grout consisting of cement and fine aggregate in the
    it

    same proportion as concrete to be placed, followed by approximately 75mm of concrete of


    et

    regular mix, except that the proportion of coarse aggregate shall be reduced 50%.
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    9 High strength grout for precision support of machine base and soleplates, including
    equipment subject to thermal movement, tanks, column baseplates, bridge seats, anchor
    bolts and dowels, etc., shall be a non-shrink, ready-to-use, fluid precision grout material,
    proportioned, premixed and packaged at the factory, delivered to the job site to be placed
    with only the addition of water, formwork, and curing shall be as specified.

    8.3.3 Placing

    1 Concrete shall be placed in its final position before initial set has commenced and shall not
    be subsequently disturbed. All concrete shall be placed within 15 min of mixing unless carried
    in purpose made agitators.

    2 Concrete shall be carefully placed in horizontal layers which shall be kept at an even height
    throughout the work. The depth of layers and time between placement of layers shall be such
    that each layer can be properly merged into the preceding layer before initial set takes place,
    the depth of layer shall be determined from the type of plant the Contractor proposes to use.
    QCS 2014 Section 05: Concrete Page 6
    Part 08: Transportation and Placing of Concrete

    3 Concrete shall be allowed to slide or flow down sloping surfaces directly into its final position
    from skips, down pipes or other placing machines or devices or, if this is not practical, it
    should be shovelled into position, care being taken to avoid separation of the constituent
    materials.

    4 Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be tipped into
    the face of the previously placed concrete.

    5 Concrete dropped into place shall be dropped vertically. It shall not strike the formwork
    between the point of its discharge and its final place in the Work, and except by approval of
    the Engineer it shall not be dropped freely through a height greater than 1.5 m. Chutes and
    conveyor belts shall be also designed so that there is no segregation or loss of mortar and
    shall be provided with a vertical tapered down pipe, or other device, to ensure that concrete is
    discharged vertically into place.

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    6 Concrete shall not be placed in standing water in the formwork.

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    7 Concrete that has attained its initial set or has contained its water content for more than 1.5
    hours or 300 drum revolutions, whichever comes first, shall not be deposited in the work.

    8
    ta
    Cold weather concreting shall be in accordance with EN 1992-1-1 or CIRIA Report 67 and
    qa
    ACI 306.

    9 Hot weather concreting shall be in accordance with Part 15 of this section.


    as

    10 Special care shall be taken to protect new concrete from the harmful effects of drying winds.
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    11 During wet weather, the concrete shall be adequately protected as soon as it is in position.
    er

    12 No concreting shall be carried out during periods of continuous heavy rain unless it is
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    completely covered during mixing, transporting and placing.

    13 No concrete shall be carried out during dust storms.


    it o

    14 Underwater placing of concrete is allowed only for unreinforced components, the placing
    et

    being effected exclusively with stationary tremies or with a bottom-opening watertight boxes
    and shall be in accordance with the requirements of design or equivalent as accepted.
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    15 Underwater concrete is to be placed continuously without interruption. For water depths up to


    1 m the concrete may be placed without tremie. In the case of water depths exceeding 1 m
    the concrete is to be placed in such a way that it does not fall freely through the water. The
    tremies must at all times dip sufficiently far into the freshly placed concrete to ensure that the
    concrete emerging from the tremie does not come into contact with the water.

    16 All work connected with the placing of concrete under water shall be designed, directed and
    inspected with due regard to local circumstances and purposes. Work shall not proceed until
    all phases and methods to be used in the placing operations have been accepted by the
    Engineer.
    QCS 2014 Section 05: Concrete Page 7
    Part 08: Transportation and Placing of Concrete

    17 Stops in concrete, at the end of a period of work, shall be made only at construction joint
    locations shown on the drawings and/or positions accepted. Where the positions of
    construction joints are not indicated on the drawings, these may be assumed, for estimating
    purposes, to occur at 5 metre intervals in foundations and retaining walls and at one-third to
    one-quarter of span in slabs and beams subject to a maximum spacing of approximately 9
    metres.

    18 At construction joint location the surface of the completed concrete shall be prepared by
    spraying, wire brushing or chipping so that it is free from all laitance, scum and loose material
    and shows a slightly roughened texture and tips of the coarse aggregate exposed. Before
    continuing concreting the exposed concrete face shall be thoroughly wetted.

    19 In the ground floor slab (where ground bearing), construction joints, crack inducer joints,
    contraction joints and expansion joints shall be incorporated into the work as appropriate.
    The spacing of construction joints, crack induced joints, contraction joints and expansion

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    joints in water retaining structures shall be shown on the design drawings

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    20 Where the positions or type of joints are not indicated on the drawings in the ground floor
    slab, the slab shall be cast in strips not more than 4.0 metres wide, in alternating sequence,
    across the width of the building. A minimum of 3 days shall elapse between the casting of

    ta
    adjacent strips. Within each strip, crack induced joints shall be provided at not more than 5.0
    qa
    metre spacing, and contraction joints shall be provided at not more than 15.0m spacing.
    Across the width of the building, construction joint shall be provided between adjacent strips
    th
    with contraction joint at every 4 construction joint.
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    21 Wherever necessary and as required by the Engineer, waterstops of a type acceptable to the
    se

    Engineer shall be embedded in the concrete. The waterstop should be made of a high
    quality material, which must retain its resilience through the service life of the structure for the
    er

    double function of movement and sealing. The surface of waterstops should be carefully
    rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good
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    tightness with or without movement of the joints, the waterstop should be provided with
    anchor parts. The cross-section of the waterstops should be determined in accordance with
    the presumed maximum water pressure and joint movements. The complete works of fixed
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    and welded connections must be carried out strictly in accordance with the manufacturers
    it

    instructions.
    et

    Engineers acceptance shall be obtained by the Contractor, prior to start of work, on the
    m

    22
    casting sequence and the layout of joints.

    23 Waterstops shall be carefully maintained in position prior to concreting on accurately profiled


    stop boards to create rigid conditions.

    24 The type of waterbar to be used shall suit the joint and purpose according to water bar
    manufacturers recommendations

    8.3.4 Compaction

    1 Concrete shall be thoroughly compacted by vibration during the operation of placing and
    thoroughly worked around the reinforcement, around embedded fixtures and into corners or
    the formwork to form a solid mass free from voids.
    QCS 2014 Section 05: Concrete Page 8
    Part 08: Transportation and Placing of Concrete

    2 When vibrators are used to compact the concrete, vibration shall be applied continuously
    during the placing of each batch of concrete until the expulsion of air has practically ceased
    and in a manner that does not promote segregation of the constituents of the concrete.

    3 Immersion type vibrators shall be capable of producing not less than 10000 cycles per
    minute, and external vibrators not less than 3000 cycles per minute.

    4 A sufficient number of vibrators in serviceable condition shall be on site to ensure that spare
    equipment is always available in the event of breakdown.

    5 Immersion type vibrators shall be inserted into the uncompacted concrete vertically and at
    regular intervals. Where the uncompacted concrete is in a layer above freshly compacted
    concrete the vibrator shall penetrate vertically for about 100 mm into the previous layer.
    Vibrators shall not come into contact with the reinforcement or the formwork. They shall be
    drawn back slowly from the mass concrete so as to leave no voids. Internal type vibrators

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    shall not be placed in the concrete in a random or haphazard manner nor shall concrete be

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    moved from one part of the work to another by means of the vibrators.

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    6 Operators shall be trained in the use of vibrators. Foremen shall have a minimum of five
    years of experience in the supervision of placing concrete

    7 ta
    Vibration of the concrete shall not be applied by way of the reinforcement.
    qa
    8 Compaction shall commence as soon as there is sufficient concrete to immerse the vibrator
    as

    and continue during the placing operations so that at no time shall there be a large volume of
    uncompacted concrete in the formwork.
    se

    9 The duration of vibration shall be limited to that required to produce satisfactory compaction
    without causing segregation. Vibration shall on no account be continued after water or
    er

    excess grout has appeared on the surface.


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    10 During the placing of all reinforced concrete, a competent steel fixer and a competent
    carpenter shall be in attendance on each concreting gang. They shall ensure the
    o

    reinforcement embedded fittings and forms are kept in position as work proceeds.
    it
    et

    8.3.5 Continuity of Concrete Work


    m

    1 Whenever instructed by the Engineer, the Contractor shall carry out the work in such a
    manner that the placing of the concrete in any particular section of the structure shall be
    executed without any interruption whatsoever from the beginning to the end of the operation.

    2 Casting of concrete shall not begin until a sufficient quantity of approved material is at hand
    to ensure continuity of operation, nor shall work begin until there is sufficient equipment in
    reserve in case of breakdown.

    END OF PART
    QCS 2014 Section 05: Concrete Page 1
    Part 09: Formwork

    9 FORMWORK ........................................................................................................... 2
    9.1 GENERAL ............................................................................................................... 2
    9.1.1 Scope 2
    9.1.2 References 2
    9.1.3 Submittals 2
    9.1.4 Quality Assurance 3
    9.2 FORMWORK MATERIALS ...................................................................................... 5
    9.2.1 General 5
    9.3 CLASS OF FINISH AND MATERIALS: .................................................................... 5
    9.3.1 Unformed surfaces 5
    9.3.2 Surface Finish Classifications 7
    9.3.3 Formwork Materials 7
    9.3.4 Exposed Concrete Surface Finishes 7
    9.3.5 Form Ties 8

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    9.3.6 Coating and Accessories 8

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    9.4 FORMWORK EXECUTION ..................................................................................... 9

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    9.4.1 General 9
    9.4.2 Trial Panels 9
    9.4.3 Formwork Face in Contact with Concrete 9
    9.4.4
    9.4.5
    Sloping Surfaces
    Temporary Openings ta 10
    10
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    9.4.6 Form Windows 10
    9.4.7 Co-ordination 10
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    9.4.8 Conduits 10
    9.4.9 Ties and Bolts 11
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    9.4.10 Chamfers 11
    9.4.11 Cambers 11
    9.4.12 Exterior Angles 11
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    9.4.13 Surface Retarders 11


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    9.4.14 Detection of Movement During Concrete Placement 11


    9.4.15 Building in Pipes 12
    9.4.16 Working Platform 12
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    9.4.17 Safe Access 12


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    9.4.18 Kickers 12
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    9.4.19 Cover Spacers 12


    9.4.20 Water Bars 12
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    9.5 REMOVAL OF FORMWORK................................................................................. 13


    9.5.1 General 13
    9.5.2 Stripping of Formwork 13
    9.5.3 Holes to be Filled 14
    9.5.4 Repair to Damaged Concrete Surfaces 14
    9.6 DELIVERY AND STORAGE .................................................................................. 14
    9.6.1 Delivery 14
    9.6.2 Storage 14
    9.7 TOLERANCES ...................................................................................................... 15
    9.8 EARLY LOADING .................................................................................................. 15
    QCS 2014 Section 05: Concrete Page 2
    Part 09: Formwork

    9 FORMWORK

    9.1 GENERAL

    9.1.1 Scope

    1 This Part includes permanent forms, temporary formwork, and falsework for structural and
    architectural cast-in-place concrete including form liners, coatings, and accessories.

    2 Related Sections and Parts are as follows:


    This Section
    Part 8, .............. Transportation and Placing of Concrete
    Part 10, ............ Curing

    .
    Part 17, ............ Structural Precast Concrete.

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    Section 11: Health and Safety
    Part 1, ............. Regulatory document
    Part 2, ............. Safety and accident prevention management/administration system
    (SAMAS)
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    9.1.2 References
    as

    1 The following standards and other document are referred to in this Part:
    se

    ACI Committee 117 ....Standard Tolerances for Concrete Construction and Materials (ACI
    117-90), American Concrete Institute, Detroit, 22 pp.
    er

    ACI Manual of Concrete Practice, Parts 2 and 5.


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    BS 8500......................Concrete
    BS 5975......................Code of practice for false work
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    BS EN 12812..............Falsework. Performance requirements and general design CP3


    it

    chapter V-2: 1972


    et

    EN 1992-1-1 ...............Eurocode 2: Design of concrete structures. General rules and rules for
    m

    buildings
    GSO EN 206-1 ...........Concrete. Specification, performance, production and conformity

    Concrete Society Technical Report No. 13

    9.1.3 Submittals

    1 Shop drawings shall include plans and sections, giving the following minimum information for
    each level:

    (a) details of individual panels


    (b) position, size and spacing of adjustable steel shores
    (c) position, size and spacing of joists, soldiers, ties
    (d) details of formwork for columns, beams, parapets, slab and kickers
    QCS 2014 Section 05: Concrete Page 3
    Part 09: Formwork

    (e) details of construction joints and movement joints


    (f) details of retaining walls and deep beams showing the position and size of ties, joints,
    soldiers and sheeting, together with detailed information on erection and casting
    sequences and construction joints
    (g) general assembly details
    (h) full calculation sheets
    (i) proposals at all penetrations through the concrete
    (j) proposed sequence of shoring and reshoring beams and slabs for different spans and
    floor heights and number of floors shored, and the stripping time for supported and
    suspended structural elements, clearly identifying the supported element and
    suspended element.

    .
    2 Scales of shop drawings shall be as follows:

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    (a) details: 1:1, 1:5, 1:10, 1:20

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    (b) construction: 1:50, 1:100
    (c) layout and Site Plan: 1:100 or 1:200

    3 ta
    The Contractor shall submit samples of all proposed formwork materials and samples of ties
    qa
    proposed for use in general situations above the water table and for fair faced concrete.

    4 The Contractor shall allow 14 days for Engineers review of submittals or samples.
    as

    5 Supply and delivery of built-in pipework should be clearly shown on the detailed construction
    se

    program to be submitted by the Contractor.


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    6 Method Statements for erection and removal of formwork shall be submitted by the
    Contractor before the start of the works for the Engineers review and approval. The Method
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    Statement shall include the Risk Assessments related to the activity.


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    7 When the formwork is to be carried out by a sub-contractor, then the pre-qualification


    documents shall be submitted for the Engineers review and approval.
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    et

    9.1.4 Quality Assurance


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    1 Formwork shall comply with the requirements of BS 5975 and EN 1992-1-1

    2 The erection of formwork and associated falsework shall be executed and supervised by fully
    qualified personnel having a minimum of five years experience.

    3 The Contractor shall obtain approval to load any particular section of the works from the
    Engineer.

    4 Formwork design shall be carried out in accordance with the Concrete Society Technical
    Report No. 13.

    5 The erected formwork shall be watertight from the ingress of external liquids and the egress
    of internal liquids. Adjustable steel supports and shores shall allow formboards and
    framework to be accurately adjusted to line and level. The Contractor shall ensure that
    adequate ground support for falsework is available, and if not shall take measures to make
    them suitable.
    QCS 2014 Section 05: Concrete Page 4
    Part 09: Formwork

    6 Formwork shall be designed to be sufficiently rigid to maintain the correct position, shape and
    profile so that the final concrete structure is within the dimensional tolerances specified
    Subpart 9.7 of this Part.

    7 Formwork shall be designed to be demountable without causing shock, disturbance or


    damage to the concrete.

    8 Soffit formwork, properly supported on shores only, shall be capable of being retained in
    position during the concrete maturing period.

    9 The design shall allow free movement and accessibility under the formwork.

    10 Shores for abnormal ceiling heights shall be specially designed.

    11 The forms shall be designed to incorporate 20 mm chamfers on exposed corners of

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    columns, walls and beams.

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    12 The design of formwork shall take into account the following:

    (a) height and rate of pour


    (b) thickness of the member
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    (c) concrete slump and density
    (d) placing temperature
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    (e) texture of finish


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    (f) construction joints


    (g) wind load
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    (h) on soffit forms (in addition to concrete weight)


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    (i) an additional live load of 2.5 kPa, or


    (ii) if a motorised cart is used, an additional live load of 3.75 kPa
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    (i) minimum design load for combined dead and live load
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    et

    (i) 6.50 kPa


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    (ii) if a motorised cart is used, 7.75 kPa


    (j) the worst combination of:
    (i) self-weight
    (ii) formwork forces
    (iii) reinforcement weight
    (iv) wet concrete weight
    (v) construction loads
    (vi) wind loads,
    (vii) incidental dynamic effects caused by placing, vibrating and compacting
    concrete
    (viii) the use of externally applied vibrators
    QCS 2014 Section 05: Concrete Page 5
    Part 09: Formwork

    (k) method of concrete discharge


    (l) access for concrete placement and vibration.

    13 Before beginning related formwork operations the Contractor shall erect a job mock-up, to a
    reasonable size including all items such as sheeting, stiffeners, soldiers, ties etc. (and
    including release agents, where used) for the following types of formwork, and shall obtain
    the approval the Engineer before proceeding:

    (a) columns
    (b) slabs and beams
    (c) staircases
    (d) fair-faced concrete (show method used to conceal tie holes) cove ties not required.

    14 Upon prior consultation, agreement of location and approval, the job mock-ups may remain

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    as part of the finished work.

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    9.2 FORMWORK MATERIALS

    9.2.1 General
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    1 Forms shall be of wood; metal or other material acceptable to the Engineer.

    2 The design of formwork shall be the responsibility of the Contractor.


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    3 Formwork shall conform to the requirements of EN 1992-1-1


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    4 Form oil and form sealer shall be of quality as acceptable to the Engineer.
    er

    9.3 CLASS OF FINISH AND MATERIALS:


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    9.3.1 Unformed surfaces


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    1 Unformed surfaces shall be classified as either:


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    et

    (a) U4, timber trowel finish


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    (b) U3, steel trowel finish


    (c) U2, brush finished
    (d) U1 other finish designated by the Engineer, such as:
    (i) Screeded Finish - Where the floor slab is to receive a screeded finish, the slab
    shall be laid to the slopes and levels shown on the drawings and the top surface
    shall be tamped whilst unset, to produce a suitable keyed surface for the receipt
    of the appropriate finishing materials.
    (ii) Floated Finish - Where a floated finish is required to the floor slabs the top
    surface shall be leveled and floated whilst unset to an uniform finish to the
    slopes and levels shown on the drawings. The floating shall be done in such a
    manner as not to bring an excess of mortar to the surface.
    QCS 2014 Section 05: Concrete Page 6
    Part 09: Formwork

    (iii) Dustproof Finish - Where concrete surfaces are required to provide a dustproof
    finish these shall be treated with two coats of accepted material. Each coat
    shall be applied with a soft brush on a clean and dry surface in accordance with
    the manufacturer's printed instructions.
    (iv) Non-slip Finish - Concrete surfaces described on the drawings as having a non-
    slip finish shall be treated with carborundum dust, evenly sprinkled on whilst the
    concrete is still green, at a rate of 1 kg/m and lightly trowelled in before final
    finishing. Alternatively, the carborundum dust may be incorporated into the finish
    by means of a mechanical power float.
    (v) Hardened Finish - Where a hardened finish is required to the floor slabs these
    shall be treated with three coats of accepted material. Each coat shall be
    applied with a soft brush on a clean and dry surface in accordance with the
    manufacturer's printed instructions.

    .
    (vi) Finishing Unformed Surfaces - Finishing unformed surfaces shall be tamped,

    l
    .l.
    floated, trowelled or brushed as defined below and shown on the drawings.

    rw
    1. Type T - Tamped surfaces shall be formed by levelling and tamping the
    concrete to produce a uniform plain or ridged surface, surplus concrete
    being struck off by a straight edge immediately after compaction. It is

    ta
    also the first stage of the following finish.
    qa
    2. Type F - Floated surfaces shall be uniform surface which has been
    worked no more than is necessary to remove screed marks by hand with
    a wood float or by power float of a type acceptable to the Engineer. The
    as

    surface shall not be floated until the concrete has hardened sufficiently.
    se

    3. Type ST - Steel trowelled shall be a hard, smooth finish, free from trowel
    marks and formed with a steel trowel under firm pressure. Trowelling shall
    er

    not commence until the moisture film has disappeared and the concrete
    has hardened sufficiently to prevent excess laitance from being worked to
    ov

    the surface. If laitance is brought to the surface it shall be removed.


    4. Type BR - Brushed shall be formed before the concrete has hardened by
    o

    drawing a wire broom over the concrete surface at right angles to the
    it

    traffic flow to give an average texture depth of 1mm.


    et

    5. For ground slab concrete shall be treated with sodium silicate or a similar
    m

    dust preventive coating. This must be applied in accordance with the


    manufacturer's instructions.

    2 The type of finish will be specified on the drawings or as directed by the Engineer. Before
    beginning any concrete pour with unformed surfaces, the Contractor shall obtain confirmation
    of the type of finish required from the Engineer.

    3 Initial finishing of unformed surfaces shall commence immediately after the placing and
    compaction have taken place.

    4 Suitable access boards or platforms shall be provided to allow access to all parts of
    unformed surfaces to be finished.

    5 Where a protective treatment or topping layer is to be applied to the concrete the


    manufacturers and suppliers recommendations shall be followed concerning the required
    finish.
    QCS 2014 Section 05: Concrete Page 7
    Part 09: Formwork

    6 Brush to finish shall be obtained by carrying out a steel trial finish and then using a suitable
    stiff nylon brush dragged lightly across the surface.

    7 The addition of small quantities of water to the finishing trowel will be permitted to aid
    finishing.

    9.3.2 Surface Finish Classifications

    1 Finishes to formed surfaces of concrete shall be classified as F1, F2 and F3, or such other
    special finish as may be designated.

    2 Where the class of finish is not designated:

    (a) all internal concrete shall be finished to Class F3


    (b) external concrete below ground shall be finished to Class F1

    l .
    .l.
    (c) where surfaces are to be tanked by covering with paint or sheeting, the formwork
    shall be capable of achieving a finish suitable for the proposed tanking as directed by

    rw
    the Engineer.

    9.3.3 Formwork Materials


    ta
    qa
    1 Formwork for Class F3 finish shall be lined with as large panels as possible of non-staining
    material with a smooth unblemished surface such as sanded plywood or hard compressed
    fibre board, arranged in a uniform approved pattern and fixed to back formwork by oval nails.
    as

    (a) the same type of lining shall be used throughout any one structure
    se

    (b) unfaced wrought boarding or standard steel panels shall not be permitted.
    er

    2 Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or
    plywood arranged in a uniform approved pattern free from defects likely to detract from the
    ov

    appearance of the surface.

    3 Formwork for Class F1 finish shall be constructed of timber, or of any suitable materials
    o

    which will prevent loss of grout when the concrete is vibrated.


    it
    et

    9.3.4 Exposed Concrete Surface Finishes


    m

    1 Exposed concrete surfaces shall have a Class F3 finish.

    2 Care shall be taken to ensure that the finish to the exposed concrete on the external and
    internal surfaces are of the highest quality to produce a smooth concrete surface of uniform
    texture and appearance without visible imprint of grains, steppings or ridges.

    3 The resulting concreting shall be free from honeycombing, stains, fins, lipping, nail and screw
    marks, raised grain marks or any other imperfections and shall be of a uniform surface
    texture and colour. Only very minor surface blemishes caused by entrapped air or water will
    be accepted provided that they do not exceed 0.5% by area of each square metre considered
    separately and in addition they shall not be concentrated in a manner such that they are
    noticeable.

    4 Formwork to the wetted surfaces of water retaining structures shall be Class F3

    5 All exposed concrete corners and edges shall have 20 mm by 20 mm chamfers.


    QCS 2014 Section 05: Concrete Page 8
    Part 09: Formwork

    6 Grooves in exposed concrete shall be formed by attaching tapered planed timber battens
    accurately aligned to the face of formwork.

    9.3.5 Form Ties

    1 Form ties shall conform to the following requirements:

    (a) factory-fabricated
    (b) adjustable in length
    (c) use removable or snap-off metal form ties
    (d) designed to prevent formwork deflection and to prevent spalling concrete surfaces on
    removal
    (e) no metal shall be left closer than the applicable level of cover to the surface of the

    .
    concrete

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    .l.
    (f) holes larger than 10 mm diameter in the concrete surface, when using snap ties shall

    rw
    not be permitted
    (g) form ties shall have a factor of safety not less than 1.5.

    ta
    qa
    9.3.6 Coating and Accessories

    1 Form coatings shall be commercial formulation form-coating compounds that will not bond
    as

    with, stain, nor adversely affect concrete surfaces requiring bond or adhesion, nor impede the
    wetting of surfaces to be cured, shall be used. The use of form coatings shall be strictly in
    se

    accordance with the manufacturer instructions.


    er

    2 Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil
    to prevent adherence of the concrete.
    ov

    3 Forms for exposed surfaces shall be coated with oil before reinforcement is placed. Forms
    for unexposed surfaces may be thoroughly wetted with water in lieu of oiling, immediately
    o

    before placing of concrete except during freezing weather.


    it
    et

    4 Excessive oiling of the forms shall not be permitted in order to prevent discoloration of the
    m

    cement plaster. Where concrete surface is to be painted, the form-oil must not affect the
    bond between concrete and paint.

    5 Care shall be taken to prevent the oil from coming in contact with reinforcement or with
    concrete at construction joints. Any oil on reinforcing steel shall be removed.

    6 Release agents shall not be used where concrete surfaces receive special finishes or applied
    coatings which may be affected by the agent, unless approved by the Engineer.

    7 Fillet and chamfer strips shall be PVC or timber to the approval of the Engineer.

    8 Tapes to be used to seal joints of formwork panels for smooth finish concrete shall be plastic
    faced adhesive tape to the approval of the Engineer.

    9 Precast concrete moulds shall be rigid steel, wood or fibreglass moulds.

    10 Flashing reglets shall be galvanised steel of the longest possible length.


    QCS 2014 Section 05: Concrete Page 9
    Part 09: Formwork

    9.4 FORMWORK EXECUTION

    9.4.1 General

    1 Where formwork to external faces will be permanently exposed, all horizontal and vertical
    formwork joints shall be so arranged that joint lines will form a uniform pattern on the face of
    the concrete.

    2 Where the Contractor proposes to make up the formwork from standard sized manufactured
    formwork panels, the size of such panels shall be approved by the Engineer before they are
    used in the construction of the Works.

    3 The finished appearance of the entire elevation of the structure and adjoining structures shall
    be considered when planning the pattern of joint lines caused by the formwork and by the

    .
    construction joints to ensure continuity of horizontal and vertical lines.

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    .l.
    4 Masonry nails or similar items shall not be used to fix formwork of the like to permanent

    rw
    concrete works.

    9.4.2 Trial Panels

    ta
    qa
    1 The trial panels shall comprise surfaces that have unformed surfaces and formed surfaces
    F1, F2 and F3.
    as

    2 The concrete cast from the job mock-up shall be used to assess the acceptability of the
    Contractors workmanship for finishing.
    se

    3 If the finishing is deemed unacceptable by the Engineer, the Contractor shall prepare a
    er

    further mock-up with a particular class of finish.


    ov

    4 The job mock-ups shall be retained during the course of the works to allow comparative
    inspection, with production concreting and finishing and for the purpose of colour comparison
    to ensure colour consistency.
    it o

    9.4.3 Formwork Face in Contact with Concrete


    et

    1 Faces of formwork in contact with concrete shall be free from adhering foreign matter,
    m

    projecting nails and the like, splits or other defects, and all formwork shall be clean and free
    from standing water, dirt, shavings, chippings or other deleterious matter.

    2 Joints between forms and tie holes shall be watertight to prevent the escape of mortar or the
    formation of fins or other blemishes on the face of the concrete.

    3 The Contractor shall verify lines, levels and measurement before proceeding with formwork
    erection.

    4 The formwork surface shall be made clean and free from any foreign and deleterious matter,
    prior to start the concrete pour.

    5 In hot weather, the surface of the formwork shall be sprayed with water in order to lower the
    temperature, prior to start the pour.
    QCS 2014 Section 05: Concrete Page 10
    Part 09: Formwork

    9.4.4 Sloping Surfaces

    1 Formwork shall be provided for the top surfaces of sloping work where the slope exceeds
    15 from the horizontal (except where any such top surface is specified as a spaded finish).

    2 The formwork shall be anchored to enable the concrete to be properly compacted and to
    prevent flotation.

    3 Care shall be taken to prevent air being trapped under the sloping formwork.

    9.4.5 Temporary Openings

    1 The Contractor shall provide temporary openings for inspection of the inside of the formwork
    and for the removal of water used for washing down. The openings shall be formed as to be
    easily closed before placing concrete.

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    2 Temporary opening shall be avoided in the case of fair faced concrete.

    rw
    9.4.6 Form Windows

    1
    ta
    The Contractor shall provide windows in forms wherever directed by the Engineer or
    necessary for access for concrete placement and vibration.
    qa
    2 The windows shall be of a size adequate for tremies and vibrators spaced at maximum 1.8 m
    as

    centres horizontally.

    3 Any windows shall be tightly closed and sealed before proceeding to place concrete at a
    se

    higher level.
    er

    9.4.7 Co-ordination
    ov

    1 The Contractor shall ensure that the work of other trades in forming and setting openings,
    slots recesses, chases, sleeves, bolts, anchors and other inserts is fully co-ordinated.
    it o

    9.4.8 Conduits
    et

    1 Conduits or pipes shall be located so as not to reduce the strength of the construction.
    m

    2 In no case shall pipes other than conduits be placed in a slab 125 mm or less in thickness.

    3 Conduits embedded in a concrete slab shall not have an outside diameter greater than
    one-third the thickness of the slab nor be placed below the bottom reinforcing steel or over
    the top reinforcing steel.

    4 Conduits may be embedded in walls provided they are not larger in outside diameter than
    one-third the thickness of the wall, are not spaced closer than three diameters on centre, and
    do not impair the strength of the structure.

    5 Embedded pipes and conduits shall be supported independently from reinforcing steel in a
    manner to prevent metallic contact and thereby prevent electrolytic deterioration.

    6 Pipes and conduits where embedded shall be placed as nearly as possible to the centre line
    of the concrete section.
    QCS 2014 Section 05: Concrete Page 11
    Part 09: Formwork

    7 Conduits, piping, and other wall penetrations or reinforcements shall be subject to the
    Engineers review and approval.

    8 Conduits shall be fixed properly to avoid any displacement during concreting and prevent
    coming in contact with the forms.

    9.4.9 Ties and Bolts

    1 The position of ties passing through concrete shall be subject to the approval of the Engineer.

    2 Ties, bolts or other devices shall not be built into the concrete for the purpose of supporting
    formwork without the prior approval of the Engineer. The whole or part of any such supports
    shall be capable of removal so that no part remaining embedded in the concrete shall be
    nearer to the surface than the cover required for reinforcement.

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    9.4.10 Chamfers

    .l.
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    1 Chamfer moulding strips shall be positioned on the exposed corners of columns and beams.

    9.4.11 Cambers

    1 ta
    If required, cambers shall be as shown on the Drawings.
    qa
    2 The depth of beams at all points in the span, where cambers are used, shall be as shown on
    as

    the Drawings.

    3 Allowance shall be made for compression and settlement of the formwork on line and level.
    se

    9.4.12 Exterior Angles


    er

    1 All exterior angles to concrete exposed to view in the completed structure shall be cast to the
    ov

    true angles evenly throughout the length.


    o

    2 Care shall be taken to ensure that no waviness occurs along the angle and that no spalling
    it

    occurs to the concrete on removal of the formwork.


    et

    9.4.13 Surface Retarders


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    1 Surface retarders shall not be used on any formwork surface in contact with concrete unless
    expressly authorised by the Engineer.

    9.4.14 Detection of Movement During Concrete Placement

    1 Devices of telltale type shall be installed on supported forms and elsewhere as required to
    detect formwork movements and deflection during concrete placement.

    2 Where required slab and beam cambers shall be checked and correctly maintained as
    concrete loads are applied on forms.

    3 Workmen shall be assigned to check forms during concrete placement and to promptly seal
    all mortar leaks.
    QCS 2014 Section 05: Concrete Page 12
    Part 09: Formwork

    4 The forms shall be checked during concreting in order to identify any displacement and
    provide corrective actions immediately.

    9.4.15 Building in Pipes

    1 Pipes and pipe specials through concrete walls and floors shall as far as possible be
    positioned and built in during construction. They shall be located exactly in the positions
    shown on the Drawings and shall be true to line and level.

    2 The Contractor shall take particular care to ensure that fully compacted concrete is in contact
    with the pipe at all points.

    3 Where it is not practicable to cast pipes and specials in the concrete, boxholes shall be
    formed in the shuttering.

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    4 The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger

    .l.
    in size than will give adequate clearance for the subsequent positioning and grouting in of the

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    pipe. The sides of the boxhole shall be provided with a tapered central annular recess to
    provide a positive key. The boxhole shall be provided with a grout hole and, at the top of the
    central annular recess, a vent hole. The boxhole shall be stripped with the main shuttering

    ta
    and the concrete surface thoroughly cleaned and roughened.
    qa
    5 When the pipe is later fixed, the remaining hole shall be reshuttered and filled with non-shrink
    epoxy grout or non-shrink concrete. In the case of water retaining structures, the Contractor
    as

    shall ensure that the measures adopted shall provide a finished joint which is resistant
    against and free from leakage.
    se

    9.4.16 Working Platform


    er

    1 Safe working platform shall be provided according to Section 11 (Health and Safety).
    ov

    9.4.17 Safe Access


    o

    1 Safe access shall be provided for the workers, inspectors, and other users according to
    it

    Section 11 (Health and Safety).


    et

    9.4.18 Kickers
    m

    1 Kickers shall be provided for walls and columns

    2 The kickers shall be water tight in order to prevent any grout loss.

    9.4.19 Cover Spacers

    1 Cover spacers shall be used in order to maintain the required cover between the formwork
    and reinforcement.

    9.4.20 Water Bars

    1 In the case of watertight constructions water bars or equivalent, as approved by the Engineer,
    shall be used at joints.
    QCS 2014 Section 05: Concrete Page 13
    Part 09: Formwork

    9.5 REMOVAL OF FORMWORK

    9.5.1 General

    1 The Engineer shall be notified in writing before the removal of any formwork.

    2 The Contractor, under no circumstances, shall strike the formwork until the concrete has
    attained adequate strength to resist damage, in particular to arises and features.

    3 Concrete shall be thoroughly wetted as soon as the forms are first loosened and shall be kept
    wet during the removal operations and until the curing media is applied.

    4 A potable water supply with hoses having fine fog spray attachments shall be ready at each
    removal location before operations are commenced.

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    5 The forms after removal shall be cleaned and prepared for subsequent use.

    .l.
    rw
    9.5.2 Stripping of Formwork

    1 The period of time elapsing between the placing of the concrete and the striking of the

    ta
    formwork shall be approved by the Engineer after consideration of the loads likely to be
    qa
    imposed on the concrete and shall in any case be not less than the periods shown in
    Table 9.1
    as

    2 Stripping of the formwork within the time limits listed above does not relieve the Contractor
    from successfully crushing test cubes and achieving the specified compressive strength
    se

    results.
    er

    3 Notwithstanding the foregoing the Contractor shall be held responsible for any damage
    arising from removal of formwork before the structure is capable of carrying its own weight
    ov

    and any incidental loading.

    4 Where finished surfaces have re-entrant angles, the formwork shall be removed as early as
    o

    possible, within the time limits set above, to avoid shrinkage cracks.
    it
    et

    5 The formwork shall be carefully stripped to avoid sudden shocks from the removal of
    wedges, or vibration which might cause damage to the concrete.
    m

    6 Reshoring to beams and slabs shall be placed immediately after stripping formwork.
    Table 9.1
    Stripping Times of Formworks
    Minimum Period Before
    Type Of Formwork Stripping (Times Are From
    Concrete Placement)
    Beam sides, walls and column 1d
    Soffits of slabs (props left under) 4d
    Soffits of beams, joists and girders (props left under) 10 d
    Props to slabs 11 d
    Props to beams 15 d
    QCS 2014 Section 05: Concrete Page 14
    Part 09: Formwork

    9.5.3 Holes to be Filled

    1 Holes formed in concrete surfaces by formwork supports or the like shall be filled neatly with
    non-shrink grout.

    2 The Contractor shall clean and scarify any hole that is to be filled with non-shrink grout.

    9.5.4 Repair to Damaged Concrete Surfaces

    1 Where the concrete surface has been damaged, the Contractor shall break out any loose,
    broken or cracked concrete or aggregate.

    2 The concrete surrounding the hole shall be then be thoroughly soaked after which the
    surface shall be dried so as to leave a small amount of free water on the surface. The
    surface shall then be dusted with ordinary Portland cement by means of a small dry brush

    l .
    until the whole surface that will come into contact with the dry-pack mortar has been covered

    .l.
    and darkened by absorption of the free water by the cement. Any dry cement in the hole shall

    rw
    be removed

    3 Dry-pack material shall then be placed and packed in layers having a compacted thickness in

    ta
    accordance with the manufacturers instructions. Compaction shall be carried out by the use
    of a hardwood stick and a hammer and shall extend over the full area of the layer, particular
    qa
    care being taken to compact the dry-pack against the side of the hole. After compaction the
    surface of each layer shall be scratched before further loose material is added
    as

    4 The hole shall not be over-filled and the surface shall be finished by layering a hardwood
    se

    block against the dry-pack fill and striking the block several times. Steel finishing tools shall
    not be used and water shall not be added to facilitate finishing.
    er

    5 The surface of the concrete shall be rubbed down smooth with carborundum and water in an
    ov

    approved manner within three days of removing the formwork. Holes left after removal of
    such supports shall be neatly filled with non-shrink grout of a suitable consistency and
    matching colour.
    it o

    9.6 DELIVERY AND STORAGE


    et
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    9.6.1 Delivery

    1 The delivery of formwork materials shall be done in such a manner that damage can be
    prevented.

    9.6.2 Storage

    1 Formwork should be stored, after cleaning and preparing for reuse if used before, in such a
    manner that access to all different materials is available.

    2 Materials which can be affected by weathering shall be stored in appropriate buildings or


    under cover.
    QCS 2014 Section 05: Concrete Page 15
    Part 09: Formwork

    9.7 TOLERANCES

    1 The concrete work shall be constructed to an accuracy which shall permit the proper
    assembly of components and installations and shall be compatible with the finish. The
    accuracy of the work shall be within the tolerances shown on the Drawings or specified
    elsewhere and, in the absence of any other requirements, shall comply with the following:
    All laying out dimensions 5 mm
    Sections of concrete members 5 mm

    Surface of foundations against ground 10 mm

    Top surfaces of foundations, bases and piers 20 mm

    .
    5 mm

    l
    Surface level of floor slabs (5m straight edge)

    .l.
    Surface level of floor slabs to datum 10 mm

    rw
    Plumb of columns and walls in storey height 5 mm

    ta
    Plumb of columns and walls in full building height (for each
    storey) above the top of foundation:
    qa
    20m building height 20 mm
    150m building height 20 m (1/1000) of height
    building height 150 m 150 mm
    as

    5 mm
    se

    Inside faces of elevator shafts in storey height


    er

    Inside faces of elevator shafts in full building height (for each


    storey) above the top of foundation:
    ov

    20m building height 10 mm


    150m building height 20 m (0.5/1000) of height
    o

    building height 150 m 75 mm


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    et

    9.8 EARLY LOADING


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    1 The Contractor should note that the loading from the falsework and wet concrete, during the
    construction of a floor, will not exceed the permissible loading on the floor immediately below.
    Consequently two of the floors immediately below the one being constructed will need to be
    used, to share the loading.

    2 While propping through two floors, the Contractor shall ensure, that the props beneath the
    floor last constructed are released over its full extent as soon as the concrete has achieved
    sufficient strength to support itself plus any superimposed loading, but not sooner than the
    periods given in Table 9.1. The props shall then be re-tightened so that these may be used
    to share the construction loading from the floor above.

    3 Not withstanding the requirements of this Section for the removal times for formwork, the
    following provisions shall apply to early loading of concrete.
    QCS 2014 Section 05: Concrete Page 16
    Part 09: Formwork

    4 Concrete shall at no time be subject to loading including its own weight which will induce a
    compressive stress in excess of 0.33 of the actual compressive strength of the concrete at
    the time of loading or 0.33 of the specified 28 d characteristic strength whichever is the lower.
    For the purpose of this clause the assessment of the strength of the concrete and the stress
    produced by the loads shall be subject to the agreement of the Engineer.

    5 If, due to his method of construction, the Contractor wishes to place an imposed load on the
    structure, he shall arrange for additional cubes to be cast at the point of the structure to be
    loaded and these cubes will be crushed to monitor the compressive strength in accordance
    with BS EN 12390-3 Compressive strength of test specimens. The Contractor shall submit
    calculations showing the stresses induced by any proposed temporary loads to be placed on
    the structure.

    6 No superstructure load shall be placed upon finished piers or abutments until the Engineer
    has given his approval in writing and in no case shall any load be placed until the curing

    l .
    period is complete.

    .l.
    rw
    7 Deck slabs of bridges shall only be opened to traffic or construction equipment and plant
    when authorised by the Engineer and in no case until the curing period is complete.

    END OF PART ta
    qa
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    et
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    QCS 2014 Section 06: Road Works Page 1
    Part 01: General

    1 GENERAL ............................................................................................................... 2
    1.1 RELATED DOCUMENTS & REGULATIONS ................................................ 2
    1.2 BENCH MARKS AND MONUMENTS............................................................ 2
    1.2.1 General 2
    1.2.2 Permanent Monuments 2
    1.2.3 Setting Out 3
    1.3 EXISTING GROUND LEVELS....................................................................... 3
    1.4 MATERIALS TESTING .................................................................................. 4
    1.5 NUCLEAR DENSITY TESTING DEVICES .................................................... 5
    1.6 TEMPORARY FENCING ............................................................................... 5
    1.7 ROAD OPENING ........................................................................................... 5
    1.8 CONCRETE WORKS .................................................................................... 5
    1.9 STANDARDS AND CODES OF PRACTICE ................................................. 6

    l .
    1.10 TRAFFIC MANAGEMENT ............................................................................. 6

    .l.
    1.11 ARMED FORCES .......................................................................................... 6

    rw
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    et
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    QCS 2014 Section 06: Road Works Page 2
    Part 01: General

    1 GENERAL

    1.1 RELATED DOCUMENTS & REGULATIONS

    1 The information given in this Part is supplemental to QCS Section 1 - General. Reference
    should be made to Section 1 General prior to referring to the clauses in this part of the
    specification which cover specific requirements for roadworks and are additional to Section 1
    - General.

    2 The Government specifications, regulations, notices and circulars mentioned in QCS Section
    1 General are amended and complemented by this Specification as detailed hereafter. In
    the case of any ambiguity or discrepancy the provisions of this Specification shall prevail over
    the provisions of the aforementioned Government published specifications.

    l .
    1.2 BENCH MARKS AND MONUMENTS

    .l.
    rw
    1.2.1 General

    1 The Contractor shall consult the Survey Section of the Ministry of Municipal Affairs and
    ta
    Agriculture prior to any earthworks or site clearance to determine if the work is likely to
    qa
    disturb survey marks.

    2 If the survey section require a survey mark to be moved the Contractor will be responsible for
    as

    recreating the survey mark to an approved design and specification, and for re surveying the
    point using survey companies approved by the Survey Section.
    se

    3 On the Practical Completion of the Works the Survey Section will issue a certificate stating
    er

    that all survey marks, whether disturbed or otherwise, by the Contractor have been reinstated
    or protected to the satisfaction of the Survey Section.
    ov

    4 In the event of failure to comply with the requirements of this Clause the Government, without
    prejudice to any other method of recovery, may deduct the costs of any remedial work after
    o

    the Practical Completion date, carried out by Survey Section from any monies in its hands
    it

    due to or which may become due to the Contractor.


    et
    m

    5 All pertinent levels, lines and locations must be checked and verified by the Contractor before
    commencing the Works.

    1.2.2 Permanent Monuments

    1 At the time of substantial completion of the whole of the works, a schedule and plan drawings
    of all remaining Project related and supplementary bench marks and monuments shall be
    prepared and transmitted to the Engineer. All project related bench marks and monuments
    made permanent as above will be shown on the as-built plans, including the co-ordinates and
    level information for each.

    2 Certain bench marks and monuments determined by the Engineer shall be made into
    permanent bench marks and monuments.
    QCS 2014 Section 06: Road Works Page 3
    Part 01: General

    3 Fabrication and installation of bench marks and monuments shall be as shown on the
    drawings or in the specifications and shall include attaching warning reflectors and painting if
    required. Each bench mark and monument shall be set accurately at the required location
    and elevation and in such manner as to ensure its being held firmly in place.

    4 The Contractor may request the Engineer's approval for concrete monuments, markers and
    posts supplied by an established commercial manufacturer, whose capability of producing
    survey monuments has been well established by both testing and performance. Written
    approval shall be obtained prior to installation of the units on the project.

    1.2.3 Setting Out

    1 The level datum for the works shall be the Qatar Datum as defined by the PWA.

    2 The works shall be set out to the Qatar national grid as defined by the PWA. The Contractor

    l .
    will be supplied with the details and grid reference of setting out monuments.

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    rw
    3 The works shall be set out in accordance with the standard specification of the PWA.

    4 Before commencing the works the Contractor shall obtain from the Engineer all information

    ta
    pertaining to project related bench marks and monuments bearing local grid co-ordinates.
    qa
    5 After the Contractor takes possession of the Contract Drawings and has noted all the existing
    bench marks, he shall carry out at his own expense the setting out of the works, definition of
    as

    levels, centre lines and slopes, all in accordance with the Drawings.

    6 The Contractor shall be responsible for the true and proper setting out of the work in relation
    se

    to original points, lines and levels of references given in the Drawings and for the accuracy of
    the positions, levels, dimensions and alignment of all parts of the work, and for any delay or
    er

    loss resulting from errors made in completing the setting out of the work.
    ov

    7 The Contractor shall protect, preserve and be responsible for all existing bench narks, pegs
    and boundary marks and shall keep these in place or replace them when necessary either in
    o

    their positions or in other approved positions.


    it
    et

    8 Setting out shall be approved by the Engineer before commencing the Works, but such
    approval shall in no way relieve the Contractor of his responsibility for the correct execution of
    m

    the works.

    1.3 EXISTING GROUND LEVELS

    1 The Contractor will survey cross-sections of the site prior to the commencement of works in
    any section.

    2 The Contractor shall include in his critical path programme the date by which survey work
    should be completed in each section of the site. No works may commence in any section
    prior to the programme date without the written approval of the Engineer.

    3 Sections will be prepared at such intervals as are necessary to give a representative record
    of existing conditions and in no case will the intervals exceed 50 metres.
    QCS 2014 Section 06: Road Works Page 4
    Part 01: General

    4 The Engineer may choose to carry out his own survey of the site and in such cases will give
    the Contractor 48 hours notice of his intention to carry out survey work in any particular
    section of the Site.

    5 The Contractor may nominate a representative to be present to observe the survey. If, having
    been given such notice, the Contractor fails to appoint a representative or if the
    representative should fail to be present during the survey work, the Engineer shall proceed
    with the survey which shall be deemed to have been prepared in the presence of the
    Contractor.

    6 The Contractor shall prepare drawings showing the various cross-sections obtained from the
    above survey.

    7 The original of the drawings shall be signed by the Engineer and the Contractor as an agreed
    record of the existing ground levels.

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    8 A copy transparency of each original drawing will then be given to the Engineer. These

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    drawings shall be deemed to be the Contract Drawings replacing the original.

    1.4 MATERIALS TESTING


    ta
    qa
    1 Reference should be made to the requirements for the provision of facilities and equipment
    for the testing of materials given in Section 1.
    as

    2 In addition to these requirements the Contractor shall provide a fully equipped site laboratory
    or shall arrange for materials and samples to be transported to the Ministry of Environment
    se

    (MOE) for testing or otherwise specified by the Engineer or the Project Documentation.
    er

    3 In addition the Contractor shall provide suitable facilities at the asphalt batching plants to
    enable the Engineer to carry out all necessary tests on the raw materials and mixes. Such
    ov

    facilities will be subject to the Engineer's approval and the preparation of asphalt mixes shall
    not be allowed until the facilities have been approved by the Engineer.
    o

    4 Approved equipment shall be maintained on site at all times to:


    it
    et

    (a) Determine the laying and rolling temperature of bituminous materials.


    m

    (b) Check surface tolerance by using a straightedge and wedges or rolling straightedge.
    (c) Carryout soil grading shape, classification, moisture content and compaction tests, as
    required.
    (d) Carryout in situ dry density tests.
    (e) Carryout bitumen extraction.

    5 Equipment shall also be made available when required by the Engineer to take 150 mm
    diameter cores from the carriageway.

    6 The Engineer may require samples of materials to be delivered to the MOE for additional
    tests.
    QCS 2014 Section 06: Road Works Page 5
    Part 01: General

    1.5 NUCLEAR DENSITY TESTING DEVICES

    1 No person or company will be permitted to determine in-situ density by mean of a nuclear


    density measuring device without complying with the following regulations:

    (a) Each device shall have a valid Calibration Certificate issued by the MOE.
    (b) Persons operating the device shall hold a valid authorised user certificate issued by the
    MOE.
    (c) During the operation of the device the person operating it and any assistants shall
    wear a suitable film badge or a personal radiation warning alarm. Copies of radiation
    exposure report of the film badges should be submitted on monthly basis to the MOE.

    1.6 TEMPORARY FENCING

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    1 Temporary fencing shall be appropriate to the usage of the adjoining land and unless

    .l.
    otherwise described on the drawings may be of a type selected by the Contractor taking into

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    account the usage of the adjoining land subject to the approval of the Engineer.

    2 As soon as the Contractor is placed in possession of any part of the site he shall immediately

    ta
    erect fencing on the boundaries of the land as shown on the Drawings. In places where
    permanent fencing cannot be erected immediately or where none is required, the Contractor
    qa
    shall erect, and when and where required re-erect and maintain, temporary fencing and
    subsequently take down and remove as necessary.
    as

    3 The Contractor shall not use barbed wire in areas accessible to the general public. Access
    se

    shall be made in temporary fencing as necessary for the use of the occupiers of adjacent
    lands.
    er

    4 If temporary fencing is removed temporarily for the execution of any part of the Works it shall
    ov

    be reinstated as soon as possible and in the meantime, subject and without prejudice to the
    Conditions of Contract, the gap in the fencing shall be patrolled so that no unauthorised entry
    onto adjoining land takes place.
    it o

    5 Temporary fencing shall remain in position either until it is replaced by permanent fencing or
    et

    until its removal on completion of the Works, unless otherwise described in the contract or
    directed by Engineer.
    m

    1.7 ROAD OPENING

    1 Road openings shall be carried out in accordance with the procedures laid down in The Code
    of Practice and Specification for Road Openings in the Highway, prepared by the Ministry of
    Industry and Public Works, January 1992.

    2 Newly compacted bituminous courses shall not be opened to traffic until they have cooled to
    ambient temperature. Longer periods may be applied during the summer months for heavily
    trafficked roads at the discretion of the supervising engineer

    1.8 CONCRETE WORKS

    1 All concrete works shall be carried out in accordance with the requirements of Section 5.
    QCS 2014 Section 06: Road Works Page 6
    Part 01: General

    2 Concrete works shall include; mass concrete, reinforced concrete, in-situ concrete, precast
    concrete and prestressed concrete.

    3 Concrete works shall be deemed to include reinforcement, formwork and all the other
    materials procedures and requirements covered by Section 5 - Concrete.

    1.9 STANDARDS AND CODES OF PRACTICE

    1 The standards, codes of practice and other reference documents referred to in the roadworks
    section of the specification are listed in the first clause of each of the parts of the
    specification.

    2 Unless otherwise agreed with the Engineer a full set of these documents shall be provided by
    the Contractor within 30 days of the commencement of the contract. These documents shall
    be kept at the site and shall be available at all times for the use of the Engineer and his staff.

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    1.10 TRAFFIC MANAGEMENT

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    1 The Contractor shall comply with all instructions given by the Qatar Traffic Police in relation to
    traffic management and road safety.
    ta
    qa
    1.11 ARMED FORCES

    1 The Contractor shall comply with all reasonable instructions given by the Qatar Armed
    as

    Forces to allow them access to the Works and with the PWA.
    se

    END OF PART
    er
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    et
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    QCS 2014 Section 06: Road Works Page 1
    Part 10: Vehicle Crash Barriers

    10 VEHICLE CRASH BARRIERS ....................................................................... 2

    10.1 GENERAL REQUIREMENTS ........................................................................ 2


    10.1.1 Scope 2
    10.1.2 References 2
    10.1.3 Performance Requirements 3
    10.1.4 Submittals 3
    10.1.5 Quality Assurance 4
    10.1.6 Maintenance 5
    10.2 STEEL WIRE ROPE BARRIERS .................................................................. 5
    10.2.1 General 5
    10.2.2 Component Ropes 5

    .
    10.2.3 Tail Rope 6

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    10.2.4 Safety Check Rope 6

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    10.2.5 Posts 6
    10.2.6 Anchorage Frames 7
    10.2.7 Other Components 7
    10.2.8 Installation
    ta 8
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    10.3 TENSIONED CORRUGATED BEAM SAFETY FENCE ................................ 9

    10.4 UNTENSIONED CORRUGATED SAFETY FENCE .................................... 10


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    10.5 OPEN-BOX BEAM SAFETY FENCE ........................................................... 11


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    10.6 TENSIONED RECTANGULAR HOLLOW SECTION SAFETY


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    FENCE ......................................................................................................... 12
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    10.7 MARKERS FOR BARRIERS ....................................................................... 12


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    10.8 CRASH CUSHIONS AND TERMINALS ...................................................... 12


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    et

    10.9 VEHICLE BARRIER UNITS (VBU) .............................................................. 13


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    10.10 TEMPORARY CONCRETE BARRIERS ...................................................... 13

    10.11 ALUMINIUM BRIDGE PARAPET ................................................................ 14


    QCS 2014 Section 06: Road Works Page 2
    Part 10: Vehicle Crash Barriers

    10 VEHICLE CRASH BARRIERS


    10.1 GENERAL REQUIREMENTS

    10.1.1 Scope

    1 This section of the specification covers the supply, installation and foundation requirements
    of the following representative types of vehicle crash barriers. The definition of each type of
    barrier is given in the relevant section of the specification.

    (a) steel wire rope barriers.


    (b) tensioned corrugated beam safety fence
    (c) untensioned corrugated beam safety fence

    .
    (d) open box beam safety fence

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    (e) tensioned rectangular hollow section safety fence

    rw
    (f) permanent concrete barriers
    (g) temporary concrete barriers
    (h) aluminium bridge parapet.
    ta
    qa
    2 This section of the specification does not cover the design criteria for deciding on the type of
    barrier to be applied in a particular situation.
    as

    3 Related Sections and Parts


    se

    This Section
    Part 12 Fencing
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    Section 5 Concrete
    ov

    10.1.2 References
    o

    1 The following standards and other documents are referred to in this Part:
    it

    BS 4............................Structural steel sections


    et

    BS 302........................ Wire ropes for cranes, excavators and general engineering purposes
    m

    BS EN 13411-1 ..........Specification for Thimbles for wire ropes


    BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
    BS 970........................Wrought steels for mechanical and allied engineering purposes
    BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
    BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
    BS 1490......................Aluminium and aluminium ingots for engineering purposes
    BS EN ISO 2081 & BS EN ISO 2082, Electroplated coatings of cadmium and zinc on iron
    and steel
    BS EN 10264..............Round carbon steel wire for wire ropes
    BS 3416......................Bitumen based coatings for cold application
    BS EN 1011................MIG Welding of aluminium and aluminium alloys
    BS 4320......................Metal washers for general engineering purpose
    BS 4464......................Spring washers for general engineering and automobile purposes
    BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
    BS 6579......................Safety fences and barriers for highways
    QCS 2014 Section 06: Road Works Page 3
    Part 10: Vehicle Crash Barriers

    BS EN 1317................"Highway parapets for bridges and other structures. Part 1.


    Specification for vehicle containment parapets of metal construction
    BS EN 10025..............Hot rolled products of non-alloy structural steels - Technical delivery
    conditions.
    DTP, Manual of contract documents for highway works - volume 1 specification series 400
    DTP, Manual of contract documents for highway works - volume 3 standard details

    ASTM D 1248 .............Specification for Polyethylene Plastics Moulding and Extrusion


    Materials US, Department of Transportation Research Report NCHRP,
    No. 230.

    ISO 9002 ....................Quality assurance system for production and installation

    10.1.3 Performance Requirements

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    1 The vehicle crash barriers shall present a continuous smooth face to an impacting vehicle so

    .l.
    that the vehicle is redirected without turning on its side or rolling over to a course that is

    rw
    nearly parallel to the barrier face and with a lateral deceleration which is tolerable to the
    vehicle occupant. The vehicle shall be redirected without rotation about either its horizontal
    axis (spinning out) or vertical axis (overturning) and the rate of lateral deceleration shall be

    ta
    such as to cause minimum risk of injury to the passengers.
    qa
    2 The vehicle shall be directed so that no part of the vehicle crosses the line parallel with and
    4 m from the original alignment of the traffic face of the fence or barrier within a distance of
    as

    10 m from the last point of initial impact in the direction of the adjacent traffic flow.
    se

    3 On impact the safety fence or barrier shall contain and redirect a vehicle of a certain mass
    travelling at a certain velocity at an angle of incidence of 20 degrees to the fence or barrier.
    er

    4 The level of vehicle containment shall be lower, normal or higher as designated, with the
    ov

    following value for vehicle mass and vehicle speed.


    Containment Vehicle Mass, kg Vehicle Speed, km/h
    o

    Normal 1500 113


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    Lower 1500 80
    et

    Higher 5000 80
    m

    The centre of gravity of the test vehicle prior to impact shall be 500 mm above the ground.
    5 All the components of a vehicle crash barrier shall be designed to achieve a serviceable life
    of not less than 20 years except for the use of temporary concrete barriers where the nominal
    service life shall not be less than 10 years.

    10.1.4 Submittals

    1 The Contractor shall submit details of previous installations of the vehicle crash barrier over a
    10-year period, indicating the system, its location and the type of highway.
    QCS 2014 Section 06: Road Works Page 4
    Part 10: Vehicle Crash Barriers

    2 For the particular crash barrier system proposed, the Contractor shall submit a detailed
    report giving the results of vehicle impact tests, and may include photographs and video
    recordings. The report shall be from an internationally recognised laboratory approved by the
    Engineer. The report shall describe in detail the arrangements for the test including vehicle
    weight, speed, impact area, full details of the test vehicle guidance and measuring systems
    and speed measurements. The report shall include photographs showing the results of the
    test. The report shall give full details of the actual vehicle speed, approach angle, vehicle
    interaction and fence movement of vehicle and roll, yawl and pitch of the vehicle movement
    after exit from safety fence. The report shall include details of the safety fence damage and
    the vehicle damage.

    3 Crash cushions and terminals. The Contractor shall make a detailed technical submission
    that will include drawings indicating the layout for the system at different locations. The
    Contractor shall also submit design calculations for the system for head on impact and side
    impact. These calculations shall indicate the reduction in G force or all vehicles of specified

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    weight and speed. The submission shall contain the precise specification of the individual

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    elements of the system, installation procedures, fixing details and fully dimensioned scale

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    layout drawings. The Contractor shall submit reports from the highway authority where the
    particular barrier system has been used showing details of vehicle collisions and the results
    of such collisions.
    ta
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    4 The Contractor shall submit calculations to show that post foundations can withstand an
    overturning moment of 6.0 kNm.
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    5 The Contractor shall submit full technical details of the safety fence system proposed
    including post to beam connection details of beam joints and post to beam connection details
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    of posts, and details of tensioning assembly.


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    6 The Contractor shall submit calculations showing the required size and details of the lifting
    eyes for permanent and temporary concrete barriers for the designated barrier details.
    ov

    10.1.5 Quality Assurance


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    1 Vehicle crash barriers shall have been tested by an approved Testing establishment such as
    it

    the UK Transport and Research Laboratory. The Engineer shall decide what is an approved
    et

    Testing establishment.
    m

    2 The manufacturer shall operate an approved quality assurance system complying with ISO
    9002 for the fabrication and supply of components used in the vehicle safety barriers. Only
    components complying with the manufacturers specifications may be used.

    3 The supplier shall submit certification showing that tensioned rectangular hollow section
    safety fence systems have been tested in accordance with the requirements of the UK
    Transport and Research Laboratory.

    4 Crash cushion and terminal systems shall have been satisfactory tested following the
    procedures set down in the US Department of Transportation Research Report NCHRP, No.
    230. The installation of the system shall be supervised by a representative of the
    manufacturer with a minimum of five years of experience in the use of the system.
    QCS 2014 Section 06: Road Works Page 5
    Part 10: Vehicle Crash Barriers

    10.1.6 Maintenance

    1 For vehicle crash barriers, crash cushion and terminal systems the Contractor shall supply:

    (a) four copies of the installation and maintenance manual


    (b) a relevant spare parts list for the system showing the recommended set of spare parts
    needed to restore one system to its original condition after a head on impact
    (c) if specified elsewhere in the Contract the Contractor shall supply spare parts for the
    system
    (d) current prices of spare parts
    (e) profile of a local agent

    10.2 STEEL WIRE ROPE BARRIERS

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    10.2.1 General

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    1 Steel wire rope safety fence barriers shall be supplied and installed in accordance with the
    designated dimensions and details shown on the contract drawings. The post details,

    ta
    spacing, anchorage, size shapes and general layout shall be as per the details shown on the
    contract drawings.
    qa
    2 Wire rope barriers shall consist of either two or four, tensioned, galvanised, steel-wire ropes.
    The type of system to be specified shall be as shown on the contract drawings.
    as

    3 Four wire rope barriers shall consist of two upper ropes located in a slot at the top of the steel
    se

    posts and two lower ropes interwoven along the fence between each pair of ropes. The
    ropes shall be joined and tensioned by means of screws at the designated intervals.
    er

    4 The ends of the ropes shall be attached to anchor blocks and embedded in the ground.
    ov

    Steel posts may be located in the ground either as driven posts or in concrete footings. In the
    case of any obstruction, the Contractor shall propose an alternative steel post, surface
    o

    mounted to the equivalent of strain. Steel posts shall be removable and replaceable.
    it
    et

    5 The supply and installation of steel wire safety fence barriers is to be carried out in
    accordance with BS 6579, except as modified herein.
    m

    10.2.2 Component Ropes

    1 Component ropes shall consist of steel wire ropes fitted with end terminals.

    2 The rope shall be 19 mm diameter, 3 x 7 (fill) galvanised wire rope generally to BS 302: Part
    1 with a minimum breaking force of 173.6 kN. All wire used in the rope shall be to BS EN
    10264 galvanised normal duty. Various galvanised wire finishes may be used by agreement
    with the Engineer.

    3 The rope shall be prestressed by applying a cyclic loading until all initial extension has been
    removed. After prestressing the rope will exhibit a minimum modulus of elasticity of 8300
    kg/mm2 based on an area of 283 mm2.

    4 The complete component rope shall have terminals, one end right-hand thread and the other
    left-hand thread.
    QCS 2014 Section 06: Road Works Page 6
    Part 10: Vehicle Crash Barriers

    5 The fittings shall be attached to the rope whose length measured over the extreme ends of
    the threaded portion of the fittings shall be 153.35 m, -0/+25 mm. Other special lengths of
    rope with identical construction may be detailed as necessary for specific applications.

    6 All threaded terminals shall be made from steel to BS 970: Part I Grade 65SM13 and either
    cadmium plated to BS EN ISO 2081 & BS EN ISO 2082 class B or alternatively galvanised to
    BS EN ISO 1461.

    7 A test will be carried out to destruction on a threaded terminal test piece consisting of a
    terminal and a length of rope such that the minimum test length is 600 mm. This assembly
    shall have a minimum breaking force of 164.6 kN.

    10.2.3 Tail Rope

    .
    1 Tail ropes shall be short lengths of rope fitted with threaded terminals at both ends that are

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    used to connect component ropes to anchors. Tail ropes shall be supplied to the site
    prefabricated.

    rw
    2 Tail ropes are of identical construction and specification to the component ropes but of

    ta
    different overall length. These ropes must also be prestressed.
    qa
    3 The length of the fitted rope measured over the extremities of the threaded portions of the
    screwed terminals shall be 6 m 10 mm.
    as

    4 Tail ropes shall be terminated in one of two ways using identical terminals to those specified
    for component ropes: with right-hand terminations on both ends, or with a right-hand at one
    se

    end and a left-hand termination at the other.


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    10.2.4 Safety Check Rope


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    1 Safety Check Ropes are steel wire ropes fitted with end terminations. The rope itself shall be
    8 mm diameter 6 x 19 (9/9/1) IWRC galvanised wire rope to BS 302 with a minimum breaking
    o

    force of 40.3 kN. All wires used in the rope shall be to BS EN 10264 grade normal duty,
    it

    galvanised to class 'A' finish.


    et

    2 The rope shall have a galvanised heart-shaped thimble to BS EN 13411-1 capable of


    m

    accepting a 38 mm diameter pin fitted by using a pressed ferrule on one end and a forked
    terminal on the other end.

    3 The length of the rope between the centre of the 38 mm pin hole and the 9 mm pin hole shall
    be 1.8 m 0/+20 mm.

    10.2.5 Posts

    1 There are three types of posts with variations for embedded style or surface mounting: line,
    deflection and surface.

    2 All posts shall be manufactured from 6 mm section cold rolled mild steel plate to BS EN
    10025 grade Fe 50A, having a minimum yield strength of 355 N/mm2. All posts shall be
    galvanised to BS EN ISO 1461. Dimensions and tolerances of the types of posts shall be as
    designated.
    QCS 2014 Section 06: Road Works Page 7
    Part 10: Vehicle Crash Barriers

    3 Post foundations and anchor blocks shall be as per the dimensions and details designated by
    the supplier.

    10.2.6 Anchorage Frames

    1 A range of anchorage frames must be available for various locations and applications. These
    are: on the median, verge and for end/intermediate and embedded/surface mounted fixings.
    The anchorage frames shall comply with the requirements of clause 4.3 of BS 6579.

    2 End anchorage frames shall be constructed from weldable structural steel as defined in BS
    EN 10025 Grade Fe 430A with steel plate to section 4, and steel bar to section 6. Rolled steel
    channel to BS 4. All materials shall be galvanised to BS EN ISO 1461.

    3 Intermediate anchorage frames are double sided frames. All materials and finishes shall be
    as defined above.

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    4 The intermediate anchor frames may be surface mounted.

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    10.2.7 Other Components

    1
    ta
    Sockets for post foundation shall be constructed from 3 mm steel to BS EN 10025 Grade Fe
    430A. Galvanised to BS EN ISO 1461.
    qa
    2 Excluders shall be produced from high-density polyethylene type iii class C Cat 4, ASTM D
    as

    1248

    3 Rigging screws shall be used to connect component ropes together and component to tail
    se

    ropes. The rigging screws shall be the body of a rigging screw manufactured to BS 4429.
    Except for the threads which are to be right and left hand M24 x 3-7H. Each rigging screw
    er

    shall be hot dipped galvanised to BS EN ISO 1461.


    ov

    4 Steel pins used in the fork terminal on the safety check rope shall be made from BS 970
    Grade 045M10.
    it o

    5 Split cotter pins shall be in stainless steel 2.5 mm x 16 mm to BS 4320 and shall have a
    et

    retaining pin.
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    6 Nuts used to secure the threaded rope terminal to an anchor frame shall be M24 thread in
    zinc electroplated condition. Steel washers shall be M 24 to BS 4320 and fitted over the
    threaded terminal and between the nut and anchor frame.

    7 Locating hooks shall be made in stainless steel to BS 970 Part I. Nuts (for hooks) shall be M6
    to BS 3692 Grade A2.

    8 Caps for posts shall be high-density polyethylene Type III class c cat 4, ASTM D 1248

    9 Ordinary thimbles shall be size 9, fitted to safety check rope made to BS EN 13411-1.

    10 The fork terminal shall be fitted to the safety check rope shall be made to BS 970 Grade
    45 M10.
    QCS 2014 Section 06: Road Works Page 8
    Part 10: Vehicle Crash Barriers

    11 All ropes, terminals, rigging screws, posts and anchor frames are to be clearly marked with
    the manufacturers identification and the date of manufacture and the standard of
    construction.

    10.2.8 Installation

    1 Steel wire ropes safety fences shall not be used where

    (a) the length of fence at full height would be less than 37.5 m
    (b) on horizontal kerb at radius less than 600 m
    (c) on vertical sag curves of radius less than 300 m
    (d) on medians having a width of less than 3.14 m
    (e) where the height of any kerb at the edge of the adjacent surface exceeds 100 mm

    .
    (f) where high mast lighting columns are situated within 10m of the edge of the paved

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    surface
    (g) where the fence has to be connected to any other fence or building

    rw
    2 All components shall be suitably protected and supplied in packaging that prevents any
    permanent damage particularly to threaded components. Damage to metallic coating shall
    ta
    be prevented by appropriate means. Any damage found on inspection prior to installation
    qa
    shall be made good to the satisfaction of the Engineer.

    3 Component ropes and tail ropes shall be supplied on reels with a bar of diameter not less
    as

    than 450 mm.


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    4 Ropes shall not be twisted or kinked.


    er

    5 Driven line posts shall be installed to the alignment and level shown on the drawing without
    damage to the slot on the top of the post.
    ov

    6 The top of the post shall be capped with a black polypropylene excluder.
    it o

    7 The length of the line rope between any two adjacent anchors shall be not greater than
    et

    627m.
    m

    8 Tensioning between any two limits shall not proceed until the Engineer is satisfied that each
    limit is anchored sufficiently securely to resist the load effects due to tensioning.

    9 The tension shall be measured using a device approved by the Engineer.


    QCS 2014 Section 06: Road Works Page 9
    Part 10: Vehicle Crash Barriers

    10 The ambient air temperature shall be noted at the time of tensioning and adjusted as follows;

    ROPE TENSION kN AMBIENT TEMPERATURE C


    14.00 45
    16.75 40
    19.50 35
    22.25 30
    25.00 25
    27.75 20
    30.50 15
    33.25 10
    36.00 5

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    10.3 TENSIONED CORRUGATED BEAM SAFETY FENCE

    1
    ta
    Except as modified herein, tension corrugated beam safety fences shall comply with the DTP
    Manual of Contract Documents for Highway Works Specification - Volume 1, specification
    qa
    series 400.

    2 Tensioned corrugated beam safety fences are for use on high speed roads at the road edge
    as

    or on the central median in one of the following forms:


    se

    (a) Single sided for road edges.


    (b) Double sided for medians.
    er

    (c) Dual single sides for medians .


    ov

    3 In the event of an accident, the support post shall give away while the safety fence remains in
    tension absorbing the impact energy while protecting the traffic on the opposite carriageway.
    o

    The angle of deflection shall be reduced and as the vehicle decelerates it shall be redirected
    it

    towards the carriageway.


    et

    4 The barrier shall consist of a strong corrugated steel beam section mounted and tensioned
    m

    on steel universal posts. End posts shall be set in concrete and intermediate posts can be
    driven or set in concrete.

    5 Surface mounted posts may be used where there are obstructions. In all cases the end posts
    which are attached to barriers must be set in concrete.

    6 The layout and the positioning of the barrier shall be as shown on the contract drawings. The
    details and sizes and spacing of the various components shall be as shown on the contract
    drawings.

    7 The height of the centreline of the barrier shall be 610 mm above the edge of the carriageway
    unless shown otherwise on the contract drawings.

    8 There is no maximum length for installation. Where the line of the barrier is interrupted for an
    obstacle or gap, additional end anchorages shall be provided.
    QCS 2014 Section 06: Road Works Page 10
    Part 10: Vehicle Crash Barriers

    9 Where a barrier protects an individual short obstacle the barrier should extend from at least
    30 m in front of the obstacle to at least 7.5 m or more beyond it. A minimum clearance of
    1.2 m behind the barrier shall be allowed for deflection.

    10 Circular installations shall be at a radius of not less than 120 m. Tighter radii than this shall
    not be used without the written approval of the Engineer.

    11 Tensioners shall consist of two longitudinal bulbs installed in brackets and shall be positioned
    in intervals along the barrier and bolted to the corrugated beam.

    12 Beams shall be connected by lap joints using screws nuts and washers. Beams shall be
    spliced by lapping with the edge facing away from the direction of traffic. Longitudinal
    clearance between screws and slotted holes in the beams shall be removed by prising apart
    the beams. The nuts shall be tightened to a torque approved by the supplier.

    l .
    .l.
    13 Tensioning between any two limits shall not proceed until the Engineer is satisfied that each

    rw
    limit is anchored sufficiently securely to resist the load effects due to tensioning. Tensioning
    shall be carried out strictly in accordance with the system manufacturers recommendations.
    Adjustments to the tensioning shall be made for the ambient temperature at the time of

    ta
    tensioning strictly in accordance with the system manufacturers recommendations.
    qa
    14 The beam shall be completely formed, punched with holes for mounting and splicing and
    ready for assembly when delivered. It shall be uniform corrugated section straight or curved
    as

    sections, galvanising shall be carried out after fabrication and each element and end sections
    shall be marked at the point of fabrication with the manufacturers name or trade mark,
    se

    gauge and heat ( steel batch ) number and with the coating lot referenced.

    15 The barrier system shall be supplied with all required terminals and approach flares for the
    er

    particular installation situation.


    ov

    16 Safety barriers shall be erected to present a flowing alignment, with the alignment in plan not
    more than 30 mm from the prescribed alignment and no deviations in a 10 m length by
    o

    more than 15 mm from the prescribed alignment. The height of the beam shall not depart
    it
    et

    from the prescribed height by more than 30 mm nor deviate in any 10 m length from the
    prescribed height by more than 10 mm.
    m

    10.4 UNTENSIONED CORRUGATED SAFETY FENCE

    1 Untensioned corrugated safety fences shall meet the requirements of the tensioned
    corrugated safety fence except as modified herein and the fence shall not be tensioned.

    2 Untensioned corrugated safety fences can be used in low-speed situations to prevent


    vehicles crossing median and for protection at the verge.

    3 Beams shall be shaped so that there are no sharp edges protruding into traffic. Beams shall
    be connected by lap joints made in the direction of the traffic flow. The beams shall be
    formed from a 3 mm steel strip to give a corrugated cross-section. On curves less than 45 m
    radius, the beam shall be provided in preformed curves, internal or external, without any
    reduction in strength.
    QCS 2014 Section 06: Road Works Page 11
    Part 10: Vehicle Crash Barriers

    4 At terminations, the end rails shall be sloped down at a slope of approximately 1 in 6 to


    terminate just above ground level. Anchorage shall be provided by an end post set in
    concrete. Unless otherwise designated the centreline of the beam shall be 610 mm above
    the edge of the carriageway or hard shoulder.

    10.5 OPEN-BOX BEAM SAFETY FENCE

    1 Open box beam safety fences shall meet the requirements of the DTP - Manual of contract
    documents for highway works - volume 1 specification series 400 except as modified herein.

    2 The open-box beam barrier shall be used on high-speed roads where a stiffer barrier than
    the tensioned corrugated beam is required. The open-box barrier can be used for a double
    sided installation in a median.

    3 The layout, positioning, post spacing and all dimensions of the system shall be as

    l .
    designated.

    .l.
    rw
    4 The systems shall comprise a main traffic section rail element with a traffic face 150 mm
    wide. This shall be ground mounted on relatively weak Z-section posts or with hexagonal
    energy absorbing brackets bolted to a reinforced concrete wall or bridge pier. The traffic face

    ta
    shall be set to a height of 610 mm at the centreline of the rail.
    qa
    5 There is no limit to the length of the installation, but end rails shall be taken down to ground
    level and bolted to end posts to form anchors which are set in concrete.
    as

    6 Where the installed barrier exceeds 100 m in length, expansion joints are to be inserted in
    se

    the main rail.


    er

    7 The standard section length shall be 4.8 m unless otherwise designated, and this value shall
    ov

    be used on curves of radii down to 335 m.

    8 For radii between 335 m and 107 m special fish plates shall be used.
    it o

    9 For radii between 107 m and 50 m, 2.4 m rail lengths shall be used with special fish plates.
    et
    m

    10 Z-section intermediate posts shall be connected to the main rail by shear bolts and clamp
    plates into the back of the rail section.

    11 Rail sections shall be butt jointed together connected by fish plates and bolted in connection.

    12 Where a non-standard situation arises in the use of the crash barrier, the supplier shall obtain
    recommendations from the UK Transport Research Laboratory.

    13 In particularly hazardous locations where vehicles with a high centre of gravity are in use, the
    open box barrier may be installed to a double height with two protective rails. The horizontal
    centreline of the second rail shall be positioned 1 m above the adjacent carriageway. The
    two box section rails shall be connected together with vertical straps or a single shear bolt in
    the centre of each connection of the rails to longer intermediate posts.
    QCS 2014 Section 06: Road Works Page 12
    Part 10: Vehicle Crash Barriers

    10.6 TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE

    1 Tensioned rectangular hollow section safety fences shall be installed as designated. The
    position, layout dimensions and details shall be as designated.

    2 The barriers shall be used where protection is required for bridge piers lighting columns and
    other obstructions.

    3 The size of the rectangular hollow section shall be 100 mm wide x 100 mm high or
    100 mm wide x 200 mm high.

    4 The minimum recommended curve for the barrier shall be 120 m radius. Tensioners shall be
    fitted at a maximum spacing of 70.5 m and the first tensioner shall be within 50 m of the
    anchorage.

    l .
    .l.
    5 When supplied the system shall include a detailed packing list with each component

    rw
    referenced and clearly marked to the standard of manufacture and the manufacturers name
    and date of manufacture.

    10.7 MARKERS FOR BARRIERS


    ta
    qa
    1 To ensure that the vehicle crash barriers are clearly delineated, reflectorized markers shall be
    fixed to the barriers. The work shall consist of the fabrication supplied and fixing of
    as

    reflectorized markers to vehicle crash barriers and other road side obstructions.
    se

    2 Reflectorized markers shall consist of two retro-reflective faces of minimum area 4000 mm2
    on a weather proof durable backing capable of being fixed to the barrier. All metal fixings and
    er

    fittings shall be galvanised or stainless steel and approved by the Engineer.


    ov

    3 Reflectorized faces shall consist of a minimum of 210 glass beads set in a 3 mm thick tough
    durable plastic backing. The two faces of the marker shall be of the colour specified in the
    Qatar Traffic Manual unless shown otherwise in the drawing or instructed otherwise by the
    o

    Engineer.
    it
    et

    4 Reflectors shall be fixed to safety barriers and other structures where designated. Stainless
    m

    steel fixings complying with BS EN ISO 3506 grade A4 shall be used to attach markers to
    concrete. Plastic isolation washers shall be used if the marker is galvanised.

    10.8 CRASH CUSHIONS AND TERMINALS

    1 Where designated, permanent or portable energy absorbing terminal systems shall be


    provided for protection of traffic as shown on the drawings.

    2 Proposed systems shall have a proven record of satisfactory performance of at least five
    years in a number of locations.

    3 The system shall be able to withstand head on and side impacts within the specified design
    criteria. The system shall have the performance characteristics of a conventional metal
    beam guard rail for strength durability and redirectional properties.
    QCS 2014 Section 06: Road Works Page 13
    Part 10: Vehicle Crash Barriers

    4 All of the components and materials of the system shall be suitable for use in the climatic
    conditions of Qatar and shall not be liable to damage or deterioration in high temperatures or
    by prolonged exposure to direct sunlight.

    5 The system shall be such that most major components can be reused after a typical impact.

    6 All metal work used in the system shall be galvanised or stainless steel.

    7 All concrete used in the system shall meet the requirements of Section 5.

    8 No work or fabrication of the system or ordering of the materials shall be carried out until the
    Engineer has given formal approval in writing to the Contractors detailed submission.

    10.9 VEHICLE BARRIER UNITS (VBU)

    l .
    1 Vehicle barrier units and their foundations shall be as per the details and dimensions shown

    .l.
    on the drawings.

    rw
    2 Vehicle barrier units shall be mass concrete of grade C25

    3
    ta
    The barriers shall be cast in-situ in nominal 6 m length units unless designated otherwise.
    qa
    4 All the concrete materials and procedures including any steel reinforcement for the barriers
    shall comply with Section 5.
    as

    5 Forms shall be smooth and tight-fitting which can be held rigidly to the line and grade during
    se

    the placing of concrete.


    er

    6 At the option of the Contractor, the barriers may be precast in sections not exceeding 6 m in
    length. In such cases the barrier shall be reinforced to ensure that information technology can
    ov

    be safely handled and have 2 no. lifting eyes of galvanised steel cast in at the top. The
    method of casting, handling and placing of barrier sections shall be proposed by the
    o

    Contractor for approval by the Engineer.


    it
    et

    7 The joints between the barriers shall be as per the details shown on the drawings.
    m

    8 Vehicle barrier units shall be cast onto blinding concrete laid onto compacted subgrade

    10.10 TEMPORARY CONCRETE BARRIERS

    1 Temporary concrete barriers shall be used for traffic management at road diversions or
    detours where there is slow moving traffic.

    2 Temporary concrete barriers shall be as per the designated detailed dimensions. The
    barriers shall be either double or single sided.

    3 The barriers shall be cast in nominal 6 m length units unless otherwise designated.

    4 Each barrier shall have cast in at the top two lifting eyes of galvanised steel.
    QCS 2014 Section 06: Road Works Page 14
    Part 10: Vehicle Crash Barriers

    5 Where adjacent barriers are put together two galvanised steel wire eyes shall be cast in to
    the ends to allow a steel pin to be placed through the eyes and into the road surface to
    secure the barrier laterally.

    6 The Contractor shall propose the reinforcement in the precast barriers which shall be
    adequate to resist the forces and moments induced during lifting and handling.

    7 All the concrete work including any steel reinforcement for the barriers shall comply with
    Section 5 of this specification.

    8 The method of casting, handling and placing of barrier sections shall be proposed by the
    Contractor for approval by the Engineer.

    10.11 ALUMINIUM BRIDGE PARAPET

    l .
    1 The aluminium alloy parapets for installation on the bridges and retaining walls shall be

    .l.
    designed to the requirements of BS EN 1317 "Highway parapets for bridges and other

    rw
    structures. Part 1. Specification for vehicle containment parapets of metal construction".

    2 The parapet shall be designed for normal level of containment as defined by the standard i.e.

    ta
    that required to resist penetration from the following vehicles impact characteristics:
    qa
    Vehicle Saloon Car
    Mass 1500 kg
    Height of centre of gravity 600 mm
    as

    Angle of impact 2 degrees


    Speed 113 km/h
    se

    3 The parapet proposed for use shall be a three rail system of an established design the
    er

    prototypes of which have been subjected to full scale dynamic testing. The parapet design
    which shall therefore be considered exempt from further dynamic testing shall be taken from
    ov

    the list in Appendix G of BS EN 1317.

    4 The parapets supplied to the project shall be certified by the supplier as a normal
    o

    containment system complying with one of the following.


    it
    et

    5 That it complies in all respects with the design of parapet that successfully met the
    m

    requirements of Clause 26.1 or 26.5 (concerning dynamic testing) of BS EN 1317 as


    appropriate.

    6 That any modifications that have been made to the tested design comply with Clause 26.6 or
    26.7 of BS EN 1317 as appropriate.

    7 The parapet construction materials shall be as follows:


    Extruded sections Aluminium alloy 6082-T6 to BS 1474
    Castings Aluminium alloy LM6M to BS 1490
    8 The finish of the parapets shall be high quality defect free mill finish and as cast finish for
    extrusions and castings respectively.

    9 All aluminium welds shall confirm to BS EN 1011 and the requirements of BS EN 1317.
    QCS 2014 Section 06: Road Works Page 15
    Part 10: Vehicle Crash Barriers

    10 All setscrews and nuts are to be stainless steel to BS EN ISO 3506 material grade A4.
    Setscrews are to be strength class 80. Washer material is to be stainless steel to BS 1449:
    Part 2 conforming to grade A4 or A2 as defined in BS EN ISO 3506.

    11 Rail attachment and rail joint screws are to be M12 x 30 long hexagon head each complete
    with one spring washer to BS 4464 type B, and one plain washer to BS 4320 form A.

    12 Holding down bolts are to be M20 hexagon head bolts of sufficient length to give the
    engagement required in BS EN 1317.

    13 Bottom mesh fixing screws if required, are to be to the M8 long hexagon head set screws
    each complete with one spring washer, two plain washers and one M8 nut where appropriate.

    14 The holding down arrangement shall be in accordance with the requirements of BS EN 1317.

    l .
    15 Loctite grade 270 (or similar approved) to be applied on erection to all rail joint and rail

    .l.
    attachment setscrews. At the holding down bolts, contact between the stainless steel and

    rw
    aluminium baseplate shall be avoided by the use of a suitable "top-hat" insert manufactured
    from an inert material.

    16
    ta
    Underside of baseplates are to be given at least two coats of an alkali resistant bitumastic
    paint or pitch complying with BS 3416.
    qa
    17 Mesh, if required, shall be 10 gauge welded steel wire in accordance with BS EN 1317,
    as

    where appropriate. It may be galvanised, or any other finish as directed by the Engineer.

    18 Rivets shall consist of Avdel drive rivets, code 5141 or 06 37 or similar approved. Where
    se

    there is no substantial backing Avdel chrobert rivets, code 1125 06 13 with sealing pins code
    1182 06 07 or similar approved, shall be used.
    er
    ov

    19 Full details of the proposed supplier with his technical specification in English covering
    materials, main dimensions and sizes shall be submitted to the Engineer for approval before
    the Contractor places an order.
    it o

    20 Two copies of detailed shop drawings shall be submitted and the Engineer's approval
    et

    obtained before manufacture is commenced.


    m

    21 During erection, parapets shall be securely held in their correct position until all connections
    and fastenings are complete and the post fixings have attained adequate strength to the
    Engineer's approval.

    22 The finished parapets shall be true to line and level throughout their length.

    23 Panels and members shall be free from twist, and posts shall be truly vertical.

    END OF PART
    QCS 2014 Section 06: Road Works Page 1
    Part 11: Kerbs, Footways and Paved Areas

    11 KERBS, FOOTWAYS AND PAVED AREAS............................................................ 2


    11.1 GENERAL ............................................................................................................... 2
    11.1.1 Scope 2
    11.1.2 References 2
    11.1.3 Submittals 2
    11.1.4 Quality Assurance 2
    11.2 KERBS .................................................................................................................... 3
    11.2.1 General 3
    11.2.2 Materials and Manufacture 3
    11.2.3 Laying 5
    11.3 PRECAST CONCRETE PAVING BLOCKS ............................................................. 6
    11.4 LAYING PRECAST CONCRETE PAVING BLOCKS ............................................... 7

    l .
    11.5 PRECAST CONCRETE PAVING SLABS ................................................................ 8

    .l.
    11.6 CAST-IN-PLACE CONCRETE PAVED AREAS....................................................... 9

    rw
    11.7 BITUMINOUS PAVED AREAS ................................................................................ 9

    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Road Works Page 2
    Part 11: Kerbs, Footways and Paved Areas

    11 KERBS, FOOTWAYS AND PAVED AREAS

    11.1 GENERAL

    11.1.1 Scope

    1 Highway kerbs, edging kerbs for footways and other paved areas. Precast concrete paving
    slabs and precast interlocking concrete block areas.

    2 Related Sections and Parts:


    This Section
    Part 3 Earthworks
    Part 4 Unbound Pavement Materials

    .
    Part 5 Asphalt Works

    l
    .l.
    Section 5, Concrete

    rw
    Section 13, Masonry
    11.1.2 References
    ta
    qa
    1 The following standards and other documents are referred to in this Part:
    BS 812........................Testing Aggregates
    as

    BS 1377......................Methods of test for soil for civil engineering purposes


    se

    BS 7533......................Code of practice for laying precast concrete units


    BS 7533-3 ..................Laying precast concrete paving blocks
    er

    BS EN 197-1 ..............Cement composition specifications and conformity criteria for


    comments cements
    ov

    BS EN 1338................Precast concrete paving blocks


    BS EN 1339................Concrete paving flags
    o

    BS EN 1340................Concrete kerbs unit


    it
    et

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


    BS EN 12878..............Pigments for the colouring of building materials
    m

    11.1.3 Submittals

    1 The Contractor shall submit samples of the various types of concrete kerbs and other
    pavement materials for approval by the Engineer before beginning the work.

    11.1.4 Quality Assurance

    1 Tests shall be carried out on the concrete mix before beginning manufacture of precast kerbs
    and other items to ascertain the strength and surface finish requirements can be met. If the
    required strength and surface finish are not obtained, the Engineer may order revisions to be
    made in order to achieve the designated requirements.
    QCS 2014 Section 06: Road Works Page 3
    Part 11: Kerbs, Footways and Paved Areas

    2 The Engineer shall, at all reasonable times, have access to the place where paving blocks
    and other items and their constituent materials are manufactured and stored, for the purpose
    of examining and sampling the materials and finished blocks, inspecting the process of
    manufacture and marking the blocks.

    3 The laying of paving blocks shall comply with the requirements of the Code of Practice for
    Laying Precast Concrete Block Pavements and BS EN 1338 except where otherwise
    designated.

    11.2 KERBS

    11.2.1 General

    1 The following are the types of precast kerbs to be constructed where designated together

    .
    with associated channels, edgings and quadrants:

    l
    .l.
    (a) Non-mountable.

    rw
    (b) Dropped.
    (c) Flush.

    2 ta
    The dimensions and shapes of the different kerb types shall be as per the details in BS EN
    qa
    1340 unless otherwise shown on the drawings or designated in the contract.

    3 The bedding and support for such units shall be as shown on the drawings.
    as

    4 Except as modified in this Part, all precast concrete kerbs, channels, edgings and quadrants
    se

    shall be hydraulically pressed complying with BS EN 1340.


    er

    5 Kerbs shall be laid and bedded in accordance with BS 7533 on the concrete pavement slab,
    a mortar bed, the road base, or on a concrete foundation while it is still plastic or after it has
    ov

    set. All precast units shall be backed with concrete as per the designated details.
    o

    6 The use of cast-in-situ concrete for kerbs will not be permitted except with the express written
    it

    approval of the Engineer.


    et

    11.2.2 Materials and Manufacture


    m

    1 Constituent concrete materials for kerbs shall conform to the requirements designated in
    Section 5. Kerbs shall be prepared with a concrete mixture containing not less than 400
    kg/m3 of sulphate resisting Portland cement.

    2 Testing of concrete kerbs shall be carried out in accordance with the requirements of BS EN
    1340.
    QCS 2014 Section 06: Road Works Page 4
    Part 11: Kerbs, Footways and Paved Areas

    3 The aggregate shall meet the designated requirements and conform to the following
    gradation.
    Table 11.1
    Aggregate Gradation for Kerb Concrete

    Sieve mm % Passing by Weight

    19 100
    13.2 76-100
    9.50 60-80
    4.75 40-60
    2.36 22-42
    1.18 12-32

    .
    0.6 7-23

    l
    .l.
    0.3 4-15

    rw
    0.15 2-10
    0.075 0-2

    4 ta
    The 28-day compressive strength of the concrete shall be not less than 30 N/mm2
    qa
    determined on 150 mm cube specimens, and not less than 75 % of this figure after seven
    days.
    as

    5 Non-mountable kerb, dropped kerb, flush kerb and heel kerb elements shall only be precast
    se

    from concrete produced in a fully automatic batching plant.


    er

    6 Before approval of elements of commercial manufacture, cores shall be taken from a random
    sample to ascertain that the concrete strength is not less than 25 N/mm2 at 7 days.
    ov

    7 Elements shall be manufactured to the designated dimensions as standard 900 mm lengths


    o

    unless specified otherwise in the contract documents.


    it
    et

    8 Non-mountable and dropped precast kerbs shall be formed by elements 500 mm long where
    required to be laid in straight lines but may be reduced to 250 mm long where required to be
    m

    laid to curves, depending on the radii of the curves.

    9 The finished product shall be of solid appearance with clean planar faces, be free of
    segregation, honeycombing, pits, broken corners or other defects and there shall be no
    evidence of external rendering.

    10 Bull-nosed and curved faces shall be of constant radius with a smooth change from radius to
    straight.

    11 Tolerances of manufacture shall be 3 mm in any one dimension and end faces shall be truly
    perpendicular to the base.
    QCS 2014 Section 06: Road Works Page 5
    Part 11: Kerbs, Footways and Paved Areas

    12 Transverse strength requirements shall be assessed in accordance with BS EN 1338


    appendix B. The loads at failure shall not be less than the appropriate value given in Table
    11.1A.
    Table 11.1A
    Transverse strength of kerbs, channels and edgings
    Depth as tested Width as tested Load at failure
    (mm) (mm) (kN)

    150 305 22.2

    125 150 8.0

    125 255 13.3

    l .
    .l.
    50 255 5.1

    rw
    50 205 4.5

    50 150
    ta 3.3
    qa
    Dropper kerbs
    125 255 to 150 10.3
    as

    13 Water absorption requirements shall be assessed in accordance with BS EN 1338 appendix


    se

    C. The water absorption shall not exceed the appropriate value given in Table 11.1B.
    er

    Table 11.1B
    Water absorption of kerbs, channels and edgings
    ov

    Water absorption in % by mass


    o

    Kerbs, channels and quadrants Edgings


    it
    et

    3.0 3.6
    m

    11.2.3 Laying

    1 Elements shall be set on to the designated lines and grades. Under no circumstances shall it
    be permitted for levels to be set by direct measurement from pavement layers.

    2 Unless otherwise indicated, elements shall be laid either directly onto a wet-concrete base or
    onto a sand/cement (3:1) mortar bedding, 25 mm thick, on a previously laid concrete base or
    approved subbase. The dimensions of the base and concrete class shall be as designated.

    3 After kerb units have been laid, a contiguous backing of concrete shall be poured for the
    elements using steel forms, unless otherwise designated. Lateral resistance shall be
    provided to the kerbs by placing dowel bars in the backing concrete in not more than 500mm
    intervals.
    QCS 2014 Section 06: Road Works Page 6
    Part 11: Kerbs, Footways and Paved Areas

    4 No pavement layers shall be laid against kerbing until such time as the backing is completed,
    backfilled and approved by the Engineer.

    5 Joints between kerbs, shall have a width of 4 mm. These joints shall be filled completely with
    fluid sand cement mortar approved by the Engineer and the joints shall be formed again.

    6 Immediately after any concrete is in place, and for seven days thereafter, the kerbs, base,
    and backing shall be fully cured and protected from drying out and against the harmful effects
    of weather, including rain and rapid temperature changes. The method of protection shall be
    subject to the Engineer's approval. The use of coloured curing membranes will not be
    permitted. Concrete not properly cured and protected will be rejected and shall be removed
    from the site.

    7 At every 10 m interval movement joint 20 mm thick shall be formed through the concrete bed

    .
    and backing. The joint filler shall be bitumen impregnated cork board. The filler shall extend

    l
    .l.
    through the kerb, bed, backing and channel, and shall be trimmed to the finished shape of
    the kerb and channel.

    rw
    8 At access points, the kerbs, including the bed backing shall be dropped to show a face of
    25 mm or as otherwise designated.
    ta
    qa
    9 At the termination of any kerb run, the end kerb section shall be sloped down to ground level,
    if applicable, and angled away from the road at 30 degrees in accordance with BS 7533.
    as

    10 All kerbs shall be thoroughly cleaned of all extraneous materials.


    se

    11 Kerbs shall be laid within a tolerance of 3 mm, at each end of an element, to the designated
    lines and grades.
    er
    ov

    11.3 PRECAST CONCRETE PAVING BLOCKS

    1 Standard rectangular precast concrete paving blocks shall have a work size length of 200
    o

    mm and a work size width of 100 mm. Paving blocks of any other shape may be made
    it

    provided they fit within a 295 mm square co-ordinating space. The preferred work size
    et

    thicknesses are 60 mm, 80 mm and 100 mm for all types of paving blocks.
    m

    2 The actual sizes of the paving blocks as determined in accordance with BS EN 1338 shall not
    deviate from the work size dimensions by more than the following tolerances:

    Length 2 mm

    Width 2 mm

    Thickness 3 mm

    3 The binder used in making the paving blocks shall be Ordinary Portland Cement, Sulphate
    Resisting Portland Cement or Moderate Sulphate Resisting Portland Cement which complies
    with BS 4027 or ASTM C150; respectively.

    4 The aggregates used in making the paving blocks shall be Gabbro, and they shall comply
    with section 5 of QCS.
    QCS 2014 Section 06: Road Works Page 7
    Part 11: Kerbs, Footways and Paved Areas

    5 The water used in the manufacturing of the blocks shall be of drinking quality or shall be in
    conformance with section 5 of the QCS.

    6 The pigments, which are used to give colour to the paving blocks, shall comply with BS EN
    12878.

    7 The average tensile splitting strength of 16 paving blocks tested in accordance with BS EN
    1338 shall not be less than 3.6MPa and the strength of any individual block shall not be less
    than 2.9MPa and the failing load not lower than 250N/mm.

    8 The average water absorption of three tested samples shall not exceed 5% and no individual
    block shall have a water absorption greater than 6%.

    11.4 LAYING PRECAST CONCRETE PAVING BLOCKS

    l.
    1 The paving blocks shall be laid generally in accordance with BS 7533-3 and to a pattern

    .l.
    approved by the Engineer.

    rw
    2 A laying course consisting of fine aggregates (sand), which complies with the corresponding
    grading requirement given in Table 11.2, shall be constructed. The fine aggregates shall be

    ta
    placed in a moist but not a saturated condition and shall be compacted so that a laying
    qa
    course thickness of 50 mm approximately is formed. This sand layer shall be placed on a
    compacted aggregate subbase or base as indicated in the project specifications/drawings.
    as

    3 The paving blocks shall be laid on the laying course and compacted using a plate compactor
    with a plate area of not less than 0.25 m2, transmitting an effective pressure of not less than
    se

    75 kN/m2 of plate at a frequency of vibration in the range of 75 Hz to 100 Hz.

    A maximum deviation for the block paving from design levels of 6 mm shall be maintained.
    er

    4
    ov

    5 The joints between the paving blocks shall be filled with dry jointing sand by spreading it over
    the surface and brushing it into the joints. The dry sand shall be natural and shall comply with
    the corresponding grading requirement given in Table 11.2. The block paving shall be
    o

    vibrated to ensure that the joints have been completely filled.


    it
    et

    Table 11.2
    Grading for laying course & jointing sand
    m

    % Passing
    Sieve Size
    Laying Course Sand Jointing Sand

    10 mm 100
    5 mm 90-100 100
    2.36 mm 75-100 95-100
    1.18 mm 55-90 90-100
    600 m 35-70 55-100
    300 m 8-35 15-50
    150 m 0-10 0-15
    75 m 0-3 0-3
    QCS 2014 Section 06: Road Works Page 8
    Part 11: Kerbs, Footways and Paved Areas

    11.5 PRECAST CONCRETE PAVING SLABS

    1 Precast concrete paving slabs shall be hydraulically pressed, complying with BS EN 1339.

    2 The dimensions of precast concrete paving slabs shall be as per Table 3 of BS EN 1339
    unless shown otherwise on the contract drawings.

    3 Where permitted by the Engineer as an alternative, slabs 450 mm x 450 mm and smaller
    may be bedded on a layer of clean sharp sand complying with BS EN 12620 Grading C or M,
    25 mm 10 mm thick.

    4 On circular work where the radius is 12 m or less, all slabs shall be radially cut on both edges
    to the required line.

    .
    5 Transverse strength and water absorption requirements shall be assessed in accordance

    l
    .l.
    with BS EN 1339 - appendix B and appendix C; respectively. The loads at failure shall not be

    rw
    less than the appropriate value given in Table 11.3 and the water absorption shall not exceed
    the limit given in the aforementioned Table.
    Table 11.3
    ta
    Transverse strength and water absorption of flags
    qa
    Minimum load at failure for thickness
    Maximum water
    (kN)
    Flag type absorption in %
    as

    by mass
    50 mm 60 mm 63 mm 65 mm 70 mm
    se

    A 8.3 - 12.7 - -
    er

    B,C,D 11.1 - 16.9 - -


    E 9.6 - - - 18.8 4.0
    ov

    F 9.1 - - 15.4 -
    G 9.6 13.8 - - -
    it o
    et

    6 The mortar bed shall be spread only after the base has been approved by the Engineer. The
    subbase shall be tested for density and the minimum density shall be greater than 95% of the
    m

    maximum dry density.

    7 Slabs shall be laid in accordance with BS 7533 to the designated cross-section and with
    joints at right angles to the kerb.

    8 Slabs shall be bedded on a sand/cement (3:1) mortar bedding not less than 10 mm and not
    more than 40 mm thick.

    9 Unless designated elsewhere paving slabs shall be laid with close joints of between 2 to 4
    mm. After laying the joints shall be filled with sand complying with clause 8.3.3.

    10 Where designated paving slabs shall be laid with open joints of between 5 to 10mm laid in
    accordance with BS 7533.
    QCS 2014 Section 06: Road Works Page 9
    Part 11: Kerbs, Footways and Paved Areas

    11.6 CAST-IN-PLACE CONCRETE PAVED AREAS

    1 Cast-in-place concrete for footways and paved areas shall only be permitted for small areas
    where it is awkward or impractical to use one of the alternative paving materials specified in
    this part of the specification.

    2 The use of steel reinforcement bars or mesh in cast-in-place concrete slabs is not permitted.

    3 Paving shall be cast in sizes to avoid the formation of shrinkage cracks. The actual maximum
    size of area to be cast at one time will be advised by the Engineer based on the mix design
    and layer thickness shown on the drawings. The Contractor may be permitted to cast larger
    areas at one time if non-metallic fibres are added to the concrete mix to eliminate cracking. In
    such cases the maximum pour size shall be proposed by the Contractor and approved by the
    Engineer.

    l .
    4 Cast-in-place concrete for footways and paved areas shall be mixed, laid and cured as

    .l.
    described in Section 5.

    rw
    5 The grade of concrete, layout, thickness, position of joints and surface finish shall be as
    designated.

    ta
    qa
    6 Cast-in-place concrete shall be laid on a designated sub-base in accordance with Part 4.

    11.7 BITUMINOUS PAVED AREAS


    as

    1 Flexible surfacing for footways and paved areas shall be made and laid in compliance with
    se

    Part 5.
    er

    2 The type of mix and the surface treatment/finish to the paving will be as designated..
    ov

    3 Surfacing shall be laid to true levels and crossfalls and be of the designated thickness.

    4 Surfacing shall be laid on a designated sub-base in accordance with Part 4.


    it o
    et

    END OF PART
    m
    QCS 2014 Section 06: Road Works Page 1
    Part 12: Fencing

    12 FENCING ....................................................................................................... 2

    12.1 GENERAL ...................................................................................................... 2


    12.1.1 Scope 2
    12.1.2 References 2
    12.1.3 Submittals 3
    12.2 FENCING GENERALLY ................................................................................ 3

    12.3 CHAIN LINK FENCING.................................................................................. 4


    12.3.1 General 4
    12.3.2 Materials 4
    12.3.3 Gates 5

    .
    12.3.4 Finish to Components 6

    l
    .l.
    12.3.5 Construction 6

    rw
    12.4 STRAINED WIRE FENCING ......................................................................... 7
    12.4.1 General 7
    12.4.2 Materials
    12.4.3 Installation ta 8
    10
    qa
    12.5 PEDESTRIAN GUARD-RAIL ....................................................................... 11
    as

    12.5.1 Aluminium Guard Rails 11


    12.5.2 Galvanised Steel Rails 12
    se

    12.5.3 Materials and Fabrication 12


    12.5.4 Installation 13
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Road Works Page 2
    Part 12: Fencing

    12 FENCING
    12.1 GENERAL

    12.1.1 Scope

    1 This part of the specification covers the materials and installation requirements for the
    following permanent fence types. The definition of each type is given in the relevant section
    of the specification.

    (a) chainlink fencing.


    (b) strained wire fencing.
    (c) pedestrian guard-rail.

    . l
    .l.
    2 Related Sections and Parts:

    rw
    This Section
    Part 1 General
    Part 10 Vehicle Crash Barriers
    Section 5, Concrete ta
    qa
    12.1.2 References
    as

    BS 4............................Structural steel sections


    BS 970........................Wrought steels for mechanical and allied engineering purposes
    se

    BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
    BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
    er

    BS 1490......................Aluminium and aluminium ingots for engineering purposes


    ov

    BS 1722-2 ..................Strained wire fences


    BS 1722, Part 1 ..........Chain link fences
    o

    BS 1722, Part 2 ..........Rectangular wire mesh and hexagonal wire netting fences
    it

    BS 4102......................Specifications for steel wire and wire products for fences


    et

    BS 4320......................Metal washers for general engineering purpose


    m

    BS 4464......................Spring washers for general engineering and automobile purposes


    BS 4652......................Specifications for zinc rich priming paint

    BS EN 1011................Welding
    BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
    BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
    BS EN 10210-2 ..........Hot finished structural hollow sections of non alloy and fine grain steels
    BS EN 10244-2 ..........Steel wire and wire products

    ASTM A53 ..................Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated
    Welded and Seamless
    ASTM A193 ................Specification for Alloy-Steel and Stainless Steel Bolting Materials for
    High-Temperature
    QCS 2014 Section 06: Road Works Page 3
    Part 12: Fencing

    ASTM A240 ................Specification for Heat-Resisting Chromium and Chromium-Nickel


    Stainless Steel Plate, Sheet, and Strip for Pressure Vessels
    ASTM B108 ................Specification for Aluminium-Alloy Permanent Mould Castings
    ASTM B221 ................Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes,
    and Tubes
    ASTM D4364 ..............Practice for Performing Accelerated Outdoor Weathering of Plastics
    Using Concentrated Natural Sunlight
    ASTM Dl499 ...............Standard practice for filtered open-frame carbon-arc exposure of
    plastic
    ASTM G152................Standard practice for operating open flame carbon-arc light apparatus
    for exposure of non-metallic materials
    ASTM G153................Standard practice for operating endorsed arc light apparatus for
    exposure of non-metallic materials.

    l .
    ASTM G23..................Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type)

    .l.
    With and Without Water for Exposure of Non-metallic Materials

    rw
    AASHTO M181...........Chain link fence

    ta
    USA Federal Salt Spray Test (Test Standard 141 Method 6061)
    qa
    12.1.3 Submittals
    as

    1 For all fencing systems, the Contractor shall submit the following for the Engineers approval,
    before an order is placed with the manufacturer:
    se

    (a) Name and address of the factories at which the required materials will be
    er

    manufactured.
    ov

    (b) Technical submittals accompanied by a completed specification in the English


    language, catalogues and a tabulation showing the overall dimensions of each type
    and size of the required materials.
    o

    (c) Programme of delivery certified by the manufacturer and supplier.


    it
    et

    (d) Detailed drawings.


    m

    (e) Material composition certificates.


    (f) Technical information for the materials and system.

    2 The submittals shall clearly show the standard to which the material complies. All materials
    shall meet the requirements of the relevant BS. The Engineer may accept materials that
    comply to a comparable international standard if the contractor demonstrates that the
    standard is equivalent.

    12.2 FENCING GENERALLY

    1 All permanent fencing, unless otherwise designated shall be erected to present a flowing
    alignment both in plan and elevation following approximately the level of the finished ground
    along the line of the fence. The Contractor shall trim or fill the ground along the line of the
    fence when required. The fencing shall be neatly and effectively joined to existing fences and
    to other structures and parapets.
    QCS 2014 Section 06: Road Works Page 4
    Part 12: Fencing

    2 Where designated, existing fences, gates and stiles, with posts shall be carefully taken down,
    laid aside, removed or later re-erected. Fences, gates, stiles and posts which are to be re-
    erected shall be handled carefully to avoid any damage.

    12.3 CHAIN LINK FENCING

    12.3.1 General

    1 This work consists of the supply and installation of all plastic coated chain link fencing
    complete with all necessary hardware and appurtenances as designated and in conformity
    with the lines and grades directed by the Engineer.

    2 All materials to be furnished and installed shall conform to all requirements of BS1722: Part 2
    except as otherwise designated.

    12.3.2 Materials

    l .
    .l.
    1 The base metal for the manufacture of posts and braces shall conform to the requirements of
    BS1722: Part 1, except that the carbon content of steel posts shall not be more than 0.4 % if

    rw
    welding is required. Posts and braces shall be galvanised in accordance with BS EN ISO
    1461.

    2 ta
    Fence posts and braces and gate frames shall be pipe conforming to the requirements of
    qa
    Table 12.1 unless otherwise designated:

    Table 12.1
    as

    Fence posts and braces and gate frames requirements


    se

    Location Minimum O.D., mm Minimum Weight, kg/m


    er

    End, Corner, Pull Posts 60.3 5.43


    Line Posts 48.3 4.05
    ov

    Braces 42.2 3.38


    it o

    3 Posts for each side of gates shall be pipe conforming to the requirements of Table 12.2:
    et
    m

    Table 12.2
    Post dimensions for chain link fences

    Gate Opening, m Minimum O.D., mm Minimum Weight, kg/m

    1.5 60.3 5.43


    4.0 73.0 8.62

    4 All fence and gate posts (including all end and corner posts) shall be fitted with plastic or vinyl
    coated aluminium tops designed to fit securely over the posts and crowned to shed water.

    5 Changes in line where the angle of deflection is 15 or more shall be considered as corners
    and corner posts shall be installed.
    QCS 2014 Section 06: Road Works Page 5
    Part 12: Fencing

    6 Extension arms, stretcher bars, and other required fittings and hardware shall be steel,
    malleable iron or wrought iron and shall be hot dipped galvanised. All required fittings and
    hardware shall be fastened to the posts in the proper manner.

    7 Chain link fence fabric shall be galvanised steel fabric conforming to the BS1722: Part 1. The
    base metal for the fabric shall be medium high carbon hot-dip galvanised steel wire. All chain
    link fence fabric shall be woven into approximately 50 mm mesh such that in a vertical
    dimension of 600 mm along the diagonals of the openings there shall be at least 7 meshes.

    8 Between posts, chain link fabric shall be fastened to a top and bottom tension cable. The
    tension cable shall be 10 gauge galvanised steel.

    9 Tie wires and post clips shall be at least 9 gauge galvanised steel.

    .
    10 Turnbuckles and truss tighteners shall be fabricated of steel, malleable iron, or wrought iron

    l
    .l.
    and shall be hot dipped galvanised. The truss tighteners shall have a strap thickness of not
    less than 6 mm.

    rw
    11 The class of concrete for post footings shall be as designated.

    12.3.3 Gates ta
    qa
    1 Gate frames shall be constructed of not less than 42.2 mm galvanised pipe weighing
    as

    3.38 kg/m and conforming to ASTM A53. Gate frames shall be cross trussed with 9 mm
    adjustable truss rods. The corners of gate frames shall be fastened together and reinforced
    se

    with a malleable iron fitting designed for the purpose or by welding. All welds shall be ground
    smooth.
    er

    2 Chain link fence fabric designated for the fence shall be attached to the gate frame by the
    ov

    use of stretcher bars and the tie wires as designated for fence construction, and suitable
    tension connectors shall be spaced at approximately 300 mm intervals.
    it o

    3 The gates shall be hung by at least two steel or malleable iron hinges not less than 80 mm in
    et

    width, so designed as to securely clamp to the gate post and permit the gate to be swung
    back against the fence. The bottom hinge shall have a socket to take the bail end of the gate
    m

    frame.

    4 Gates shall be provided with a combination steel or malleable iron catch and locking
    attachment of approved design. Stops to hold gates open and a centre rest with catch shall
    be provided where required.

    5 All gates shall be provided with standard hardware and heavy duty padlocks with four keys
    each, the type and details of which shall be to the approval of the Engineer.
    QCS 2014 Section 06: Road Works Page 6
    Part 12: Fencing

    12.3.4 Finish to Components

    1 All posts, gate frames, rails and similar materials shall have a coating thickness of 254 to 356
    micron of a polyvinyl chloride (PVC) which has been chemically bonded to the metal surface
    with an appropriately cured primer. Final finish colour shall be as designated.

    2 Chain link fence fabric shall have a vinyl coating of minimum wall thickness of 0.559 mm over
    the galvanised substrate. The vinyl coating shall be continuously extruded (not sprayed or
    dipped) over the galvanised steel wire by the thermal extrusion process under pressures to
    352 kg/cm2 to ensure a dense and impervious covering free of voids, having a smooth and
    lustrous surface appearance.

    3 The wire shall be vinyl-clad before weaving and shall be free and flexible at all joints.

    .
    l
    4 Colours shall be stabilised and have a light fastness that shall withstand a minimum

    .l.
    WEATHER-O-METER exposure time of 4000 h without any deterioration in accordance with

    rw
    ASTM Dl499 and G23, Type E. Alternatively a sample of fencing may be subject to an
    exposure time of 2000 h at 85 C humidity in a humidity oven. The sample shall exhibit no

    ta
    colour loss, cracking, peeling, blistering or other deterioration.
    qa
    5 The vinyl-clad wire shall withstand an accelerated ageing test of 2000 hours at 62 C without
    cracking or peeling.
    as

    6 The vinyl covering shall, in addition, resist attack from prolonged exposure to dilute solutions
    se

    of most common mineral acids, sea water and dilute solutions of most salts and alkali.

    7 The pipe resin formulation shall meet the standard ASTM D4364, minimum 5000 h
    er

    WEATHER-O-METER requirement without cracking, blistering, or loss of adhesion. The


    ov

    protective resin coating shall withstand an impact resistance test (Gardner Test Method) of a
    minimum of 1850 mm/kg. Certified abrasion resistance shall be in excess of a ten minute
    blast of 5.6 kg/cm2 at 305 mm at 25 C with S230 shot at an impingement angle of 90
    it o

    without exposing the steel substratum.


    et

    8 It shall not support combustion and shall be self-extinguishing; and shall withstand a salt
    m

    spray test (Federal Test Standard 141, Method 6061 of greater than 10,000 h with no
    perceptive deterioration to coating or evidence of metal corrosion for unscored samples. For
    scored samples after exposure of 1000 h, under-cutting shall not exceed 5 mm. The
    protective resin coating shall exhibit a chemical resistance after prolonged exposure at 24 C
    to fumes.

    12.3.5 Construction

    1 Line posts shall be spaced at not more than 3.0 m intervals, measured from centre to centre
    of posts, in general, in determining the post spacing, measurement will be made parallel to
    the slope of the natural ground, and all posts shall be placed in a vertical position, except in
    unusual locations where the posts shall be set perpendicular to the ground surface if so
    directed by the Engineer.

    2 All posts shall be set in concrete footings conforming to the designated details.
    QCS 2014 Section 06: Road Works Page 7
    Part 12: Fencing

    3 End, corner, pull and gate posts shall be braced to the nearest line post with galvanised
    diagonal or horizontal braces used as compression members and galvanised 9 mm steel
    truss rods with turnbuckles or truss tighteners used as tension members.

    4 Pull posts shall be placed at locations agreed by the Engineer. They shall be placed at 200 m
    intervals between posts to which the ends of the fabric are clamped or midway between such
    posts when the distance is greater than 40 m but less than 200 m.

    5 Chain link fabric shall be fastened on the side of the posts designated by the Engineer.

    6 The fabric shall be stretched and securely fastened to the posts, and between posts the top
    and bottom edges of the fabric shall be fastened to the tension wires. Tension wires shall be
    stretched tight, the bottom tension wire shall be installed on a straight grade between posts
    by excavating at the high points of ground and in no case will filling of depressions be

    l .
    permitted.

    .l.
    rw
    7 The fabric shall be fastened to end, corner and gate posts tall with minimum 10 mm diameter
    steel stretcher bars and not less our than 3 mm by 18 mm stretcher bar bands spaced at
    maximum or 300 mm intervals. The fabric shall be fastened to line posts ends and tension

    ta
    wires with tie wires or post clips. The fasteners shall be spaced at maximum intervals of 500
    qa
    mm.

    12.4 STRAINED WIRE FENCING


    as

    12.4.1 General
    se

    1 Strained wire general and dropper fences shall be as designated and they shall comply with
    er

    BS 1722-2 with the following amendments.


    ov

    2 This part of the specification covers the requirements for materials and workmanship for
    strained wire fences of the general pattern and of the dropper pattern. Droppers are defined
    o

    as intermediate and vertical stiffeners between some or all of the wires that are used to
    it

    maintain the spacing of the wires. The droppers are not connected to the ground.
    et

    3 Strained wire fences comprise of tensioned horizontal steel wires fixed between vertical
    m

    straining posts with support angle struts and connected to intermediate posts. Posts shall be
    constructed of either steel or precast reinforced concrete and anchored in concrete
    foundations.

    4 Wire dropper fencing shall be provided at locations where it is necessary to restrict the
    access of vehicles, and camels and wandering animals.

    5 Strained wire general and dropper fences shall be of one of the types shown in Table 12.3

    6 The strained wire fences shall be coded according to the type dependant on the number of
    line wires, whether droppers are used, material used for the posts, these type references are
    given in Table 12.3. The first letter indicates that it is either a general pattern or a dropper
    pattern strained wire fence, the second letter indicates the type of posts that are used, the
    numbers give an indication of the height of the fence e.g. DC90 indicates a 0.9m high fence
    with concrete posts and droppers.
    QCS 2014 Section 06: Road Works Page 8
    Part 12: Fencing

    7 For the sake of uniformity quoted heights of those to the top wire and exclude any variation in
    ground clearance to the base, the third letter where present indicates the number of line
    wires.
    Table 12.3
    General Characteristics of Strained Fences - Fence Types
    With Concrete Height of
    With Steel Posts With Wooden Posts Spacing between
    Posts Top Wire &
    horizontal wires,
    General Dropper General Dropper General Dropper Number of
    from the top wires
    Pattern Pattern Pattern Pattern pattern Pattern Wires

    m No. mm
    DC 90 SS90 DS90 SW90 DW90 0.90 3 330,330
    SC105A DC105A SS105A DS105A SW105A DW105A 1.05 5 250,250,230,150

    .
    250,250,230,150,
    SC105B SS105B SS105B DS105B SW105B DW105B 1.05 6

    l
    .l.
    100
    250,250,230,150,

    rw
    SC120 DC120 SS120 DS120 SW120 DW120 1.20 6
    150
    250,250,230,150,
    SC135A DC135A SS135A DS135A SW135A DW135A 1.35 7

    SC135B DC135B SS135B DS135B SW135B ta


    DW135B 1.35 8
    150,150
    250,250,230,150,
    qa
    150,150,100
    DW135 250,225,225,150,
    SC135C DC135C SS135C DS135C SW135C 1.35 9
    C 125,125,100,75
    as

    225,225,200,175,
    DC180 DS180 DW180 1.80 11 175,175,150,150,
    se

    125,100
    100,100,100,100,
    er

    DC210 DS210 DW210 2.10 16


    100
    ov

    12.4.2 Materials
    it o

    1 The sizes stated for components are the minimum requirements and it is permissible to use
    et

    larger sizes except where this would adversely affect the fit of the components or where
    m

    replacement parts need to match those already present.

    2 Line wire shall comply with BS 4102 and shall be one of the following:

    3 Zinc coated low carbon steel with a nominal wire diameter of either 4.5 or 5mm

    4 Zinc coated high tensile wire with a nominal wire diameter of 3.15mm

    5 Plastic coated high tensile wire having a tensile strength of 1050 N/mm2 with a Zinc coated
    core of 3.15mm nominal core diameter and a 4 .0mm overall diameter.

    6 Stirrup wire shall comply with BS4102 and shall be of zinc coated low carbon steel with grade
    A plastic coated low carbon steel and should have a nominal wire core diameter of 2.5 mm.

    7 Barbed wire shall comply with BS 4102, shall be zinc coated and made from either low
    carbon steel or high tensile steel wire.
    QCS 2014 Section 06: Road Works Page 9
    Part 12: Fencing

    8 The materials, protective treatment, tolerances on size and general construction details of
    steel posts and struts, for strained wire fences shall comply with the requirements for chain
    link fences, except that components shall not be plastic coated unless specifically required
    under the contract documentation.

    9 The materials and tolerances on precasting of all concrete components shall comply with the
    relevant parts of section 5.

    10 The minimum concrete grade for posts shall be C25 and the minimum cement content
    should be 350 kg.

    11 The mixing, placing and compaction of the concrete shall be as per Section 5.

    12 All inserts and holes cast into precast concrete components with posts shall be adequate for
    the bolts or appurtenances to be fitted.

    l .
    .l.
    13 All holes shall be free from obstructions and accurately positioned.

    rw
    14 The minimum grade of concrete to be used for posts shall be C25 and the minimum cover to
    embedded steel in posts shall be 50mm.

    15 ta
    The dimensions of concrete fence posts and struts shall be as given in Table 12.4.
    qa
    16 Posts shall be reinforced with 4 steel reinforcing bars of the size given in Table 12.4.
    as

    17 Straining posts and struts shall not be tapered.


    se

    18 The dimensions and details of the foundations shall be as shown in the contract drawings.
    Concrete for foundations for the bases of posts and struts shall comply with the requirement
    er

    of section 5 of the specification and shall be grade C15.


    ov

    19 Straining posts shall be provided with a firm bearing struts at a point within the top of the
    length of the string posts, measured above the ground level.
    it o

    20 Straining posts shall be provided with holes for the attachment of straining fittings.
    et

    21 Where line wires are to be passed through them, struts shall be provided with either holes or
    m

    slots.

    22 Intermediate posts shall be tapered to 75mm x 75mm at the top and shall be holed to allow
    the attachment of line wires.

    23 High bolt strain shall consist of bolts of 250mm overall length, not less than 9.5mm diameter
    with an eye at one end. They should be threaded and fitted with nuts and washers.

    24 2 way eye bolt strainers shall be fitted with ring nuts. They shall be hopped and galvanised to
    BS EN ISO 1461. Widening brackets intended for attachment to the post shall be
    manufactured from mild steel flat not less than 25mm x 3mm and shall be fitted with a
    widening bolt 12mm minimum diameter with a friction type ferrule or ratchet winder.

    25 Hair pin staples shall be of not less than 3mm diameter round wire or sectional wire of the
    same cross sectional area and shall have a zinc coating complying with BS EN 10244-2.
    QCS 2014 Section 06: Road Works Page 10
    Part 12: Fencing

    26 Droppers shall be at least 65 mm longer than the distance between the top and bottom wires
    covered by them and shall be made of steel of the section not less than 0.0066 kg/m or steel
    wire or galvanised in accordance with BS EN ISO 1461.
    Table 12.4
    Concrete Fence Posts and Struts

    Intermediate Posts Strain Posts Struts


    Height
    Reinf. Reinf. Reinf.
    Length Section Length Section Length Section
    Dia. Dia. Dia.
    mm x mm x mm x
    m m mm m mm m mm
    mm mm mm
    100 x 100 5 75 x 75
    0.90 1.57 100 x 100 1.57 or or 1.50 or 6
    125 x 125 8 100 x 75

    l .
    100 x 100 5 75 x 75

    .l.
    1.05 1.72 100 x 100 1.87 or or 1.83 or 6

    rw
    125 x 125 8 100 x 75
    1.20 1.87 125 x 125 2.02 125 x 125 8 1.98 100 x 75 6
    1.35a
    and b
    2.02 125 x 125 2.17
    ta
    125 x 125 8 2.13 100 x 75 6
    qa
    1.35c 2.17 125 x 125 2.32 150 x 150 10 2.13 100 x 75 6
    1.80 2.62 125 x 125 2.77 200 x 200 12 2.73 100 x 100 8
    2.10 2.92 125 x 125 3.07 200 x 200 12 3.03 100 x 100 8
    as

    12.4.3 Installation
    se

    1 Droppers shall be securely fixed to all the line wires covered by them and be of sufficient
    er

    strength to maintain the spacing of the line wires and spread the load between them in use.
    ov

    2 The post shall be adequately braced in both directions after insertion into the wet concrete
    and support shall be maintained till the concrete is fully hardened.
    o

    3 Excavation for foundations for post and struts shall be of the minimum stipulated dimensions
    it

    at the base of the hole.


    et

    4 When erecting fence posts the concrete shall be placed in position before the
    m

    commencement of the initial set.

    5 The entire foundation hole shall be filled with concrete, the use of partly backfilled holes shall
    not be permitted. Straining posts shall be provided at the ends and corners of changes of
    direction or acute variations in level and at intervals not exceeding 150m for mild steel line
    wire or 300m for high tensile line wire in straight lengths of fence.

    6 Struts shall be provided at each straining post.

    7 Where there is a change in plan direction of the fence two struts shall be provided.

    8 Intermediate posts shall be provided at intervals measured centre to centre of posts not
    exceeding 3.5m.

    9 The number of line wires shall be as given in Table 12.3.


    QCS 2014 Section 06: Road Works Page 11
    Part 12: Fencing

    10 The top wire shall be secured with approximately 75mm below the top of the posts, each line
    wire shall be strained tightly and secured to each straining posts by either widening brackets
    attached to the post with fixing bolts or high bolt strainers passing through a hole in the post
    and secure with a nut and washer.

    11 If barbed wire is specified it shall be attached to the straining posts and intermediate posts by
    the same method as the line wire.

    12 Attachment to intermediate posts with the exception of the high tensile line wire for which
    stirrups are not permitted each line wire shall be secured to each intermediate posts by one
    of the following means;

    13 A wire stirrup pass through a hole in the posts secured to the

    14 a hairpin stapled post through a hole in the post and the ends twice bent over

    l .
    .l.
    15 A line wire pass through a hole in the post

    rw
    16 Small areas of hot dipped galvanised coating damaged by welding cutting or by excessively
    rough treatment during the transit and erection shall be renovated either by the use of melting

    ta
    point zinc alloy repair rods or powders made specifically for this purpose or by the use of at
    least 3 coats of good quality zinc paint as per BS 4652. Sufficient material shall be applied to
    qa
    provide a zinc coating at least equal in thickness.
    as

    17 Droppers shall be attached after all wires have been strained and secured in position.

    18 The interval between dropper and the posts or between adjacent droppers shall not exceed
    se

    the following:
    er

    (a) For full length droppers 2m.


    ov

    (b) For sectional droppers, bottom wires 2m.


    (c) Top wires 2.5m.
    o

    19 Where sectional droppers are used the ends of all droppers or adjacent levels of wire shall
    it

    be fixed to at least one wire common to both levels.


    et
    m

    20 When measured within 14 days of erection the settled tension in the line wire between
    straining posts at 100 m apart shall be at least 1.6 kN

    21 The method of approximately measuring the tension shall be as described in appendix F to


    BS 1722-2.

    12.5 PEDESTRIAN GUARD-RAIL

    12.5.1 Aluminium Guard Rails

    1 This Sub-section covers the requirements for the supply and installation of aluminium
    pedestrian guard-rails and accessories.

    2 Guard-rails shall be constructed to the designated line and grade and shall not reflect any
    unevenness in the founding construction. Unless otherwise designated, railing posts shall be
    vertical. For bridges, railing shall not be placed on a span until centring or falsework has been
    removed, rendering the span self-supporting.
    QCS 2014 Section 06: Road Works Page 12
    Part 12: Fencing

    3 The foundation details for the fence shall be as per the designated details and dimensions.

    12.5.2 Galvanised Steel Rails

    1 Galvanised steel pedestrian guard rails shall comply with the strength requirements of BS
    3049 Clause A and shall be fabricated to the dimensions shown on the drawings from hot
    rolled steel section and bars to BS EN 10210-2 and BS 4360, Grade 43C.

    2 The following Minimum steel section thickness shall be used:


    Rails - Sealed hollow section : 2.5 mm
    Other sections : 4.0 mm

    Posts - Sealed hollow sections : 3.0 mm


    Other sections : 5.0 mm

    l .
    3 Joints shall be welded by metal arc welding to BS EN 1011 except where shown otherwise on

    .l.
    the drawings.

    rw
    4 The guard rails and components shall be fabricated such that no burrs or sharp edges occur,
    that the finished work is free from distortion and cracks and that welded joints are fully

    ta
    bonded, form accurate fit and are finished smooth and flush with adjacent surfaces.
    qa
    5 The guard rail components shall be fixed to the posts at the lower joints by 12 mm diameter,
    80 mm long galvanised steel bolts with one galvanised steel washer through 40 x 40 x 6 mm
    as

    cleats. End units shall be purpose made to project over the posts with a rounded end.
    se

    6 Posts shall be closed at the top with a 6 mm plate having two 12.5 mm, 25 mm long dowels
    welded thereto. The holding down plate at the bottom of the post shall be a minimum of 20 x
    er

    100 x 6 mm thick.
    ov

    7 All steel posts shall be hot dip galvanized both inside and outside to BS EN ISO 1461. -end
    of specification addition.
    o

    12.5.3 Materials and Fabrication


    it
    et

    1 Material for cast aluminium guard-rail posts shall conform to the requirements of AASHTO
    M193 and ASTM B108, alloy S7A - T4 (A444 - T4).
    m

    2 Aluminium alloy extruded rail shall conform to the requirements of ASTM B221 alloy, 6061-T6
    or 6351-T5 with a minimum yield strength of 2466 kg/cm2, a minimum tensile strength of
    2677 kg/cm2 and an elongation of 10 % in 50 mm.

    3 Stainless steel hardware for aluminium railings shall be machine bolts or cap screws
    conforming to ASTM A193, grade B8, Class 2.

    4 Stainless steel flat washers and lock washers shall conform to the requirements of ASTM
    A240, Type 302.
    QCS 2014 Section 06: Road Works Page 13
    Part 12: Fencing

    5 Material 12.7 mm thick or less may be cut by shearing, sawing or milling. Material over 12.7
    mm thick shall be sawed or milled. Cut edges shall be true and smooth and free from
    excessive burrs or ragged breaks. Re-entrant cuts shall be filleted by drilling before cutting.
    Flame cutting will not be permitted. Material may be heated to a temperature not exceeding
    240 C for a period not exceeding 30 minutes to facilitate bending unless cold bending is
    required to retain the original mechanical properties of the material furnished.

    6 Rivet and bolt holes shall be drilled to finished size or stub punched smaller than the nominal
    diameter of the fastener and reamed to size. The amount by which the diameter of a stub
    punched hole is smaller than that of the finished hole shall be at least one-quarter the
    thickness of the piece. The finished diameter of circular holes shall be not more than 7 %
    greater than the nominal diameter of the fastener. Slotted bolt holes to take care of
    expansion shall be provided as designated. Anchor-bolt holes may be up to 25 % greater
    than the nominal bolt diameter with a maximum of 12.7 mm greater than the nominal bolt

    l .
    diameter.

    .l.
    rw
    12.5.4 Installation

    1 The Contractor shall co-ordinate and space the rail posts to miss any items which may be

    ta
    furnished and installed under this Contract. The Contractor shall also co-ordinate and space
    qa
    the rail posts to miss lighting poles and any other existing obstructions.

    2 Where aluminium alloys come in contact with other metals, except stainless steel, the
    as

    contacting surfaces shall be thoroughly coated with an aluminium-impregnated caulking


    compound, or a synthetic rubber gasket may be placed between the two surfaces. Aluminium
    se

    alloys shall not be placed between the two surfaces. Aluminium alloys shall not be placed in
    contact with copper, copper base alloys, lead or nickel.
    er

    END OF PART
    ov
    it o
    et
    m
    QCS 2014 Section 06: Road Works Page 1
    Part 13: Traffic Signs, Markings and Studs

    13 TRAFFIC SIGNS, MARKINGS AND STUDS ................................................. 2

    13.1 GENERAL ...................................................................................................... 2


    13.1.1 Scope 2
    13.1.2 References 2
    13.1.3 Definitions for Reflective Traffic Studs 2
    13.1.4 Submittals 3
    13.2 TRAFFIC SIGNS ........................................................................................... 3
    13.2.1 Scope of Work 3
    13.2.2 Sign Foundations 4
    13.2.3 Traffic Sign Materials 5
    13.2.4 Installation Requirements for Traffic Signs 7

    .
    13.2.5 Advance and far Advance Directional Signs 8

    l
    .l.
    13.3 PAVEMENT MARKINGS ............................................................................. 10

    rw
    13.3.1 Scope of Work 10
    13.3.2 Materials for Pavement Markings 10
    13.3.3
    13.3.4
    Application of Thermoplastic
    Performance Requirements and Testing ta 12
    13
    qa
    13.3.5 Protection of Pavement Markings 14
    13.4 TEMPORARY ROAD MARKING ................................................................. 14
    as

    13.4.1 ROAD MARKING PAINT 14


    se

    13.4.2 ADHESIVE ROAD MARKING STRIP 15


    13.4.3 REMOVAL OF ROAD MARKINGS 15
    er

    13.5 REFLECTIVE STUDS ................................................................................. 15


    ov

    13.5.1 General 15
    13.5.2 Reflectors 16
    o

    13.5.3 Reflectivity 17
    it

    13.5.4 Installation of Reflective Studs 18


    et

    13.6 NON-REFLECTIVE STUDS ........................................................................ 19


    m

    13.6.1 General 19
    13.6.2 Materials and Manufacture 20
    13.6.3 Installation 21
    QCS 2014 Section 06: Road Works Page 2
    Part 13: Traffic Signs, Markings and Studs

    13 TRAFFIC SIGNS, MARKINGS AND STUDS

    13.1 GENERAL

    13.1.1 Scope

    1 This Part covers the supply and installation of traffic signs (complete with posts and
    foundations), thermoplastic road marking, road marking paint for temporary roads and
    diversions, reflectorised studs and non-reflective studs.

    2 Related Sections and Parts:


    This Section
    Part 16, Traffic Signals

    l .
    .l.
    Section 5, Concrete

    rw
    13.1.2 References

    1 The following manuals and standards are referred to in this Part:


    Qatar Traffic Control Manual ta
    qa
    BS 381C .....................Colours for identification purposes
    BS 873........................Road traffic signs
    as

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


    strip
    se

    BS 1474......................Wrought aluminium for general engineering purposes; bar, extruded


    er

    round tubes and sections


    BS 1490......................Aluminium and aluminium alloy ingots for general casting purposes
    ov

    BS 2000, Part 58 ........Determination of softening point of bitumen (ring and ball)


    BS 3262,(Part 1) l989 .Hot applied thermoplastic road marking materials
    o

    BS 6088 1981.............Solid glass beads for Road Marking


    it

    BS EN ISO 591-1 .......Titanium dioxide pigments


    et

    BS EN ISO 1461 ........Hot dipped galvanising


    m

    ASTM A307 ................Steel anchor bolts


    ASTM C373 ................Standard test methods for water absorption
    ASTM C424 ................Test methods for crazing resistance

    CML 14-97..................Standard Method of test for determination of appearance, shape,


    dimensions
    and compressive strength of ceramic non-reflecting road studs.
    TRL Road Note 27 .....Skid resistance portable tester.

    13.1.3 Definitions for Reflective Traffic Studs

    1 Entrance Angle: The angle in the horizontal plane between the direction of incident light and
    the normal (perpendicular) to the leading edge of the stud.
    QCS 2014 Section 06: Road Works Page 3
    Part 13: Traffic Signs, Markings and Studs

    2 Observation Angle: The angle at the reflector between observer's line of sight and the
    direction of the light incident on the reflector.

    3 Specific Intensity (S.I.): The candle-power of the returned light at the chosen observation and
    entrance angles for each foot candle of illumination at the reflector on a plan perpendicular to
    the incident light.

    13.1.4 Submittals

    1 Within three weeks of acceptance of the manufacturer's tender, the Contractor shall submit
    for approval working drawings for signs posts and base plates. Fabrication shall not begin
    until approval has been given.

    2 The Contractor shall submit detailed drawings of the foundations proposed for traffic signs.

    l .
    3 The Contractor shall submit samples of the proposed materials for approval on request by

    .l.
    the Engineer before delivery to Site, at his own cost.

    rw
    4 The Contractor shall submit to the Engineer for approval three copies of his working drawings
    for all traffic sign faces both in Arabic and English. Size and style of lettering shall be as

    ta
    designated. No order shall be placed without written agreement of the Engineer and the
    Concerned Authorities.
    qa
    5 Before proceeding with drilling holes for sign foundations, the Contractor shall submit to the
    as

    Engineer for approval; the type of plant proposed for drilling holes, details of any temporary
    metal casings, proposed method of concreting and the proposed method of conduit
    se

    installation.

    13.2 TRAFFIC SIGNS


    er
    ov

    13.2.1 Scope of Work

    1 This work shall consist of furnishing and installing road signs and posts assemblies as
    o

    designated. All sign faces and lettering shall be in accordance with the Qatar Traffic Control
    it

    Manual. The required post sizes for different sign sizes shall be as tabulated in the Qatar
    et

    Traffic Control Manual. Where in this section of the specification the term designated is
    m

    used, this refers to the contract drawings and the Qatar Traffic Control Manual.

    2 The minimum depths and sizes for sign foundations shall be as per the requirements of the
    Qatar Traffic Control Manual. For each of the signs the Contractor shall submit design
    calculations for the proposed foundations.

    3 The following documents should be specifically referred to for this work;

    (a) BS 873

    (b) Qatar Traffic Control Manual

    4 Permanent traffic signs shall be reflectorised or non reflectorised illuminated and shall, in
    respect of quality, comply with the requirements of the latest editions of;

    (a) BS 873
    (b) Qatar Traffic Control Manual
    QCS 2014 Section 06: Road Works Page 4
    Part 13: Traffic Signs, Markings and Studs

    5 In the case of conflict with these specifications and the above documents, the matter shall be
    referred to the Engineer.

    6 All foundations, framing and fixings for information signs shall be suitable for local conditions.
    The design calculations shall be submitted to the Engineer for approval. The wind loads shall
    be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.

    7 A positive system of identification of signs, posts and all fittings shall be adopted. The
    reference number of the sign together with the date of manufacture shall be indicated by self-
    adhesive numbers on the reverse side of the sign in the bottom left hand corner and in a
    consistent and readily visible position on all posts and fittings. The manufacturer's name of
    trademark will not be permitted on the face of the sign. It may be affixed on the back of the
    sign, provided approval to the size and colour of the mark has been obtained from the
    Engineer. Any previously marked reference number should be transferred to new signs on
    replacement.

    l .
    .l.
    8 All road signs shall be guaranteed by the Contractor against any defect in material and

    rw
    workmanship for a period of five years from the date of completion of the Works under the
    Contract. If any defect should arise due to poor material or workmanship, it shall be rectified
    by the Contractor.

    ta
    qa
    13.2.2 Sign Foundations

    1 Sign foundations shall either be reinforced concrete columns in drilled holes or shallow
    as

    reinforced concrete spread footings. The dimensions and details of the foundations shall be
    as designated.
    se

    2 The number of anchor bolts and bolt locations and anchor bolt dimensions shall be as
    er

    designated. All anchor bolts nuts and washers shall be hot dipped galvanised to BS EN ISO
    1461. Any protruding parts to the bolt thread or nut shall be further protected by the
    ov

    application of a wax or grease impregnated tape. Any conduit cast into the foundation for
    cable access shall be mild steel, hot dipped galvanised after fabrication to BS EN ISO 1461.
    The minimum bend of conduit shall be 600 mm radius.
    it o

    3 All concrete and reinforcing steel used in the sign foundations shall be of the designated
    et

    grade and type and shall comply with the requirements of Section 5. Anchor bolts shall
    m

    2
    comply with the requirements of ASTM A307 with a minimum tensile strength of 414 N/mm .

    4 Each bolt shall be supplied with two hexagonal nuts for levelling purposes complete with
    washers.

    5 If an obstruction is encountered whilst drilling the foundation hole the Contractor shall inform
    the Engineer. The Contractor may elect to bore or drill through the obstruction depending on
    its nature or may propose to reallocate the signs slightly to avoid the obstruction subject to
    the approval of the Engineer. In either case the work is deemed to be included in the scope
    covered by this Part.

    6 The sides of excavation shall be vertical and any additional excavations carried out beyond
    that designated, for the particular post and sign being erected, shall be filled with concrete or
    granular material as directed by the Engineer.
    QCS 2014 Section 06: Road Works Page 5
    Part 13: Traffic Signs, Markings and Studs

    7 The reinforcement cage shall be securely fixed centrally about the axis of the foundation, any
    electrical conduit shall be securely fixed in position as designated before replacement of
    concrete.

    8 The top of the concrete foundation shall be finished with a steel trowel to a smooth finish.

    9 The top of the concrete foundation shall not extend more than 100 mm nor less than 50 mm
    above the finish grade level unless otherwise designated.

    10 All backfilling and compaction shall be completed before the erection of any sign on the
    structure.

    11 All excavations shall be approved by the Engineer before the sign is erected and before
    backfilling with fill or concrete as designated.

    l .
    .l.
    13.2.3 Traffic Sign Materials

    rw
    1 Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC - 1/2H, NS3-
    3/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11 swg) or from extruded
    aluminium plank sections to BS 1470, HE 9-WP, HE 9P or HE 30-WP or extruded aluminium

    ta
    alloy plank sections to BS 1474, HE 9 TE and HE 30 TF. However information signs shall be
    qa
    constructed in extruded aluminium planks, which will either be self-locking or rear fixing, and
    the aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent
    International standard.
    as

    2 All sign plates shall have clean, smooth edges cut to the required shape of the sign, and shall
    se

    be etched and degreased to the sign sheeting manufacturer's specifications before


    application of the sheeting.
    er

    3 Illuminated signs shall be covered with "Super Engineering Grade" reflective sheeting.
    ov

    4 Reflective signs shall be covered over the whole front face with "High Intensity" reflective
    sheeting. The sheeting shall be of the designated colour and shall have a manufacturer's
    o

    guarantee of not less than five years. The rear faces shall be non-reflective grey and should
    it

    give a similar life span to the sign face.


    et
    m

    5 The reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive
    using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in
    accordance with the sheeting manufacturer's instructions.

    6 Sign faces shall be formed from a single piece of reflective sheeting, but if for any reason the
    sign face must be fabricated from more than one piece of material all joints in the material
    shall be overlapped by not less than 6 mm and where sheeting is applied to extruded
    sections it shall extend over the top and bottom edges of the sections by not less than 3 mm.
    No butt joints shall be permitted and in horizontal joints the overlap shall be from the top.

    7 The corners of all direction signs shall be rounded to a radius of 75 mm.

    8 Signs constructed of aluminium sheet shall, when recommended by the Traffic Signs Manual,
    be framed on all edges using hot dipped galvanised steel angle or angle-channel of
    equivalent section.
    QCS 2014 Section 06: Road Works Page 6
    Part 13: Traffic Signs, Markings and Studs

    9 Signs constructed from extruded aluminium plank sections are to present the same flanged
    appearance on all edges of the sign by fitting an aluminium end capping to the exposed ends
    of the plank section on both sides of the sign.

    10 Where the designated sign width requires the use of more than one length of plank section,
    support beams shall be provided and positioned as approved by the Engineer.

    11 For plank type signs supported on two posts the plank rails and support beams shall be
    manufactured from one length of extruded aluminium section. One tie bar shall be fitted
    between the bottom two plank rails (or the plank rail and support beam) at the centre of the
    span between the mounting posts.

    12 Where plank type signs are supported on more than two posts, and the designated sign
    width is wider than the plank rail and support beams, the plank rail and support beam may
    comprise two or three lengths provided butt joints occur at an inner post. One tie bar shall be

    l .
    fitted between the bottom plank rail and support beam at the centre of the span between the

    .l.
    mounting posts.

    rw
    13 All stiffening and framing shall be continuous and shall prevent the sign from twisting.

    14
    ta
    All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or
    other material approved by the Engineer and shall have a sufficient cross-sectional area to
    qa
    prevent failure from thermal stresses or wind pressure or such other stresses as may be
    designated.
    as

    15 All rivet and bolt holes shall be edge-sealed with clear lacquer after the application of the
    se

    plastics sheeting.

    16 Rivets shall be spaced at not more than l50 mm apart, around the outside edge of the sign
    er

    plate and on cross braces the spacing shall be not more than 300 mm.
    ov

    17 Any rivet brought through the sign face shall be coloured to match the sign face. Any rivet or
    other device fixing sign plates to their frame work shall have a protective washer of nylon or
    o

    other approved insulating material inserted where they would be in contact.


    it
    et

    18 All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates to support
    posts shall be manufactured from stainless steel. For plank type signs, brackets and clips
    m

    shall be extruded aluminium alloy section.

    19 Saddles shall be aluminium alloy or other material approved by the Engineer and shall be
    provided with a nylon strip or other approved insulating material.

    20 There shall be full adhesion of all sheeting material including letters, symbols and borders
    and there shall be no air bubbles, creases or other blemishes.

    21 All panels, cut-out letters, numbers, borders, symbols and back grounds on reflective
    sheeting shall be carefully matched for colour at the time of sign fabrication to provide
    uniform appearance both by day and night. The sheeting manufacturer's recommendations
    on colour matching methods shall be observed. Non-uniform shading or undesirable contrast
    between reflective sheeting on any one sign will not be accepted.

    22 The edges of all applied sheeting materials including edges of all plates which make up a
    sign, letters, symbols and borders shall be sealed as designated by the manufacturer.
    QCS 2014 Section 06: Road Works Page 7
    Part 13: Traffic Signs, Markings and Studs

    23 Where required by the sheeting manufacturer the face of the sign plate shall have a coat of
    clear lacquer of a type designated by him.

    24 The top of sign support posts shall be capped with a plastic cap.

    13.2.4 Installation Requirements for Traffic Signs

    1 All sign faces shall be of the designated type, colour and size.

    2 Signs delivered for use in the project shall be in new and unused condition, except where
    otherwise designated; and shall be stored off the ground and under cover in a manner
    approved by the Engineer. Any sign damaged, discoloured or defaced during transportation,
    storage or erection shall be rejected.

    3 The position and mounting height of each sign shall be as designated.

    l .
    .l.
    4 Designated post lengths are approximate only. When progress of the work is at the

    rw
    appropriate stage the Engineer will authorise the location of each sign, with the chainage and
    offset distance from the edge of the road pavement. The Contractor shall be responsible for
    determination of the exact post lengths to provide the designated vertical clearance. Field

    ta
    cutting of posts shall be performed by sawing. Welded posts will not be permitted.
    qa
    5 All posts shall be erected vertically and where two or more posts are provided for any sign
    the faces of these posts shall be lined up and their deflection angle checked for compliance
    as

    with this Part before concreting in.

    6 For a period of 14 days after concreting in position, all posts shall be suitably braced to
    se

    prevent movement. Sign faces should not be fixed to posts until after the bracing has been
    removed and the Engineer has inspected and approved the post stability and foundations.
    er
    ov

    7 All posts shall be of the designated type and shall be protected against corrosion by hot dip
    galvanising to BS EN ISO 1461.
    o

    8 Unless otherwise designated, all signs shall be erected so that the edge and face of the sign
    it

    are truly vertical and the face is at an angle of 95 to the centreline; that is, facing slightly
    et

    away from the centreline of the lane which the sign serves. Where lanes divide or are on
    m

    sharp curves, the Contractor shall refer the orientation of the sign face to the Engineer for his
    instruction.

    9 All sign supports shall be plumbed vertical.

    10 The distance between the lower edge of the signs and the road surface shall be as
    designated.

    11 Signs shall be fastened to sign supports in accordance with the designated requirements and
    the recommendations of the sign manufacturer to the satisfaction of the Engineer.

    12 The Contractor shall at his own expense, immediately after erection and approval by the
    Engineer cover the sign in order to prevent misleading information being displayed. The
    covering shall be close weave hessian securely fixed over the face of the sign using a lacing
    of nylon cord so as not to damage the sign. The Contractor shall maintain such coverings in
    good order until receipt of the Engineer's instruction for their removal.
    QCS 2014 Section 06: Road Works Page 8
    Part 13: Traffic Signs, Markings and Studs

    13 Signs shall be thoroughly cleaned immediately before being handed over. The type of
    detergent used shall be approved by the Engineer.

    13.2.5 Advance and far Advance Directional Signs

    1 The face of the sign shall be completely covered with 3M Diamond Grade or similar approved
    reflective material complying with the following Table 13.1A for retro-reflectivity.

    Table 13.1A
    Minimum Coefficients of Retro-Reflection

    2
    (a) 4 Entrance Angle
    1
    Observation Angle

    l.
    0.2 0.33 0.5 1.0

    .l.
    White 430 300 250 80

    rw
    Yellow 350 250 200 65
    Red 110 75 60 20
    Green
    Blue
    45
    20
    33
    15 ta 25
    10
    10
    4.0
    qa
    as

    2
    (b) 30 Entrance Angle
    1
    Observation Angle
    se

    0.2 0.33 0.5 1.0


    er

    White 235 150 170 50


    ov

    Yellow 190 130 140 40


    Red 60 30 40 13
    Green 24 18 19 5
    o

    Blue 11 7 7 2.5
    it
    et
    m

    2
    (c) 90 Orientation, 40 Entrance Angle
    1
    Observation Angle

    0.2 0.33 0.5 1.0


    White 150 85 35 20
    Yellow 125 75 30 17
    Red 40 25 10 6
    Green 15 8 3.5 2.0
    Blue 6 4 1.5 0.7
    1
    Observation (Divergence) Angle the angle between the illumination axis and the
    observation axis
    2
    Entrance (Incidence) Angle The angle from the illumination axis to the retroreflector axis
    the retroreflector axis is perpendicular to the retroreflective surface.
    QCS 2014 Section 06: Road Works Page 9
    Part 13: Traffic Signs, Markings and Studs
    3
    Values for screened red colour on white sheeting may be significantly lower.

    2 The material also shall satisfy the requirements of the following Tables 13.1B & 13.1C with
    regard to colourimetric and photometric performance.

    Table 13.1B
    Chromacity factors
    1 2 3 4 Limit Y (%)
    Colour X Y X Y X Y X Y Min Max
    White .035 .305 .355 .355 .335 .375 .285 .325 40 -
    Yellow .487 .423 .545 .454 .465 .534 .427 .483 24 45

    l .
    Red .690 .310 .595 .315 .569 .341 .655 .345 3 15

    .l.
    Green .030 .398 .166 .364 .286 .446 .201 .794 3 9

    rw
    Blue .078 .171 .150 .220 .210 .160 .137 .038 1 10

    ta
    qa
    Table 13.1C
    Minimum Luminance Factors
    Colour Factor
    as

    Red 0.03
    se

    Yellow 0.24
    Blue 0.01
    er

    White 0.40
    Green 0.01
    ov
    o

    3 All plastic sheeting shall be fixed in accordance with the sheeting manufacturers instructions.
    it
    et

    4 Unless otherwise agreed by the Engineer, sign faces shall be formed from a single piece of
    plastic sheeting.
    m

    5 Where, with the agreement of the Engineer, more than one sheet is used the number of
    sheets shall be kept to a minimum.

    6 Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be
    overlapped by not less than 6 mm. The overlap on the horizontal joints shall be from the top;
    but joints in plastics sheeting shall not be permitted. The number of joints shall be kept to
    minimum.

    7 Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top
    and bottom edges of these sections by not less than 3mm.

    8 All materials comprising the sign face, including the background, border and legends shall be
    carefully matched for colour at the time of sign fabrication to provide uniform appearance
    both by day and night. The sheeting manufacturers recommendations on colour matching
    methods shall be observed.
    QCS 2014 Section 06: Road Works Page 10
    Part 13: Traffic Signs, Markings and Studs

    9 Letter, numerals, symbols and borders shall be of material compatible with the sheeting to
    which they are applied. They shall be applied in accordance with the sheeting
    manufacturers instructions.

    10 Sheeting materials including letters, numerals, symbols and borders shall be fully adhered
    with a pre-coated heat activated adhesive using a vacuum applicator equipped with a
    temperature controller and there shall be no air bubbles, creases, cracks or other blemishes.
    Application of the material shall be made using equipment specifically designed and
    manufactured for the purpose by the sheeting manufacturer and maintained according to his
    instructions. Where the sheeting manufacturer requires the assembly materials to be
    provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be
    applied at the time of fabrication of the sign face and shall be of a type specified or supplied
    by the sheeting manufacturer.

    11 Details of the graphic designs, Arabic and English legends to be used on directional and

    l .
    certain informatory signs are given on the Contract Drawings. The Contractor shall submit

    .l.
    design drawings detailing the proposed layout of all such signs for the approval of the

    rw
    Engineer prior to their manufacturer. Otherwise, the signs shall be in accordance with the
    specified regulatory, warning and informatory signs detailed in the Qatar Traffic Manual,
    Volume 1.

    ta
    qa
    13.3 PAVEMENT MARKINGS

    13.3.1 Scope of Work


    as

    1 This Work shall consist of the supply and application of thermoplastic road marking paint for
    se

    marking of the pavement as outlined herein. It shall include the marking of the centreline, the
    shoulder strip or edge, the barrier lines, the cross walks and any other markings required on
    er

    the pavement for the control and direction of the traffic.


    ov

    2 Where designated, thermoplastic road marking paint shall be used in the construction of
    rumble strips and jiggle bars. In such cases the requirements of this Part will apply except
    o

    that the thickness and profile of the thermoplastic will be as per the designated details.
    it

    3 The pavement markings shall be painted on the road to the dimensions and in the locations
    et

    designated on the drawings as per Qatar Traffic Control Manual.


    m

    4 The Contractor shall set out the markings and obtain the Engineer's approval before
    beginning the work.

    13.3.2 Materials for Pavement Markings

    1 The material used shall conform to the superimposed type British Standard Specification for
    Road Marking Materials BS 3262: Part 1. Where the materials do not conform to the BS
    the deviations shall be clearly given in reference to the relevant tables and paragraphs of BS
    3262: Part 1.

    2 Ballotini shall comply with the requirements of BS 6088.

    3 The material shall consist of light coloured aggregate, pigment and extender, bound together
    with hard wearing resins, plasticised with oil as necessary in approximately the proportions by
    weight as Table 13.1.
    QCS 2014 Section 06: Road Works Page 11
    Part 13: Traffic Signs, Markings and Studs

    Table 13.1
    Composition of Thermoplastic

    Material Composition

    Aggregate 40 %
    Ballotini 10 - 20 %
    Pigment and Extender 20%
    Binder 20 %

    4 The Contractor shall be responsible for blending the material to ensure that the performance
    requirements of this part of the specification are met. This approximate composition of the
    material as indicated above shall include the sprayed on ballotini.

    .
    5 The grading of various ingredients shall be such that the final product, when in a molten

    l
    .l.
    state, can be sprayed on the surface at a nominal 1.5 mm thickness.

    rw
    6 The aggregate shall consist of white silica sand, crushed calcite, calcined flint or quartz, or
    other approved aggregate, and the colour shall comply, with the requirements laid down in
    paragraph 4b of BS 3262: Part 1.
    ta
    qa
    7 Ballotini incorporated in the mixture shall be reasonably spherical, and free from flaws and
    not less than 80 % shall be transparent glass. The grading of the ballotini shall be as stated in
    as

    BS 6088.
    se

    8 The pigment shall be titanium dioxide in accordance with paragraph 6a (I) of BS 3262: Part 1
    and shall be not less than l0 % by weight of the mix.
    er

    9 The extender shall be whiting in accordance with paragraph 6b of Part 1 of BS 3262.


    ov

    10 For yellow material sufficient suitable yellow pigment in accordance with BS 3262 shall be
    substituted for all or part of the titanium dioxide to comply with the performance requirements
    o

    of this specification.
    it
    et

    11 The binder shall not contain more than 5 % of resin or other acidic material. It shall consist
    m

    mainly of hydrocarbon resins plasticised with mineral oil.

    12 The resins used shall be of a colour at least as pale as Grade WG resin. It shall have an acid
    value not greater than 2, and must pass the heat stability test described below.

    13 The oil used as plasticiser shall be a mineral oil with colour and viscosity as defined in
    paragraph 7a (ii) of BS 3262: Part 1; i.e., at least as pale as grade 4 on the P-R-S- Shellac
    and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 C viscosity. In addition, when heated for
    16 hours at 150 C it shall not darken excessively.

    14 The softening point of the binder shall be used only as a guide to quality control, and the
    behaviour of the thermoplastic shall be judged from the performance tests described below.

    15 The viscosity of the melted binder at the spraying temperature must be such as to produce a
    thermoplastic mix of the required spraying properties.
    QCS 2014 Section 06: Road Works Page 12
    Part 13: Traffic Signs, Markings and Studs

    16 The temperature limits imposed by BS 3262: Part 1 for materials based on resin shall not
    apply. Temperatures up to 220 C may be used; at these temperatures the material shall not
    discolour in the time required for its use.

    17 Containers shall be made of a material which does not contaminate the contents and will
    protect the contents from contamination.

    18 The capacity of each container shall be not less than 25 kg or more than 100 kg.

    19 Each container shall be clearly marked with the manufacturer's name, batch number and
    date of manufacture.

    20 Testing for the composition of the material and the grading of the aggregate shall be carried
    out in accordance with the methods in BS 3262 except as modified by this part of the

    .
    specification. The composition of the laid material as found on analysis shall comply with

    l
    .l.
    Table 13.2 & Table 13.3;

    rw
    Table 13.2
    Proportion of Constituents
    Percent by Weight
    Constituent
    ta Minimum Maximum
    qa
    Binder 18 22
    as

    Aggregate, pigment and extender and ballotini 78 82


    se
    er

    Table 13.3
    ov

    Grading of Combined Aggregate Pigment and Extender


    Percent by Weight
    BS Sieve (mm)
    o

    Minimum Maximum
    it

    0.850 100 -
    et

    0.600 75 95
    m

    0.300 35 65
    0.075 25 35

    13.3.3 Application of Thermoplastic

    1 Application shall be by mobile sprayer, either hand-propelled or self-propelled.

    2 The road surface shall be dry, and free of loose, detritus mud, or other extraneous matter.

    3 All existing markings of more than 1 mm thick shall be removed completely before new
    markings are applied.

    4 A tack coat should not be necessary when the thermoplastic is applied to carriageways.
    Where it is considered necessary to use a tack coat, this shall be rubberised type
    recommended by the manufacturers of the thermoplastic material.
    QCS 2014 Section 06: Road Works Page 13
    Part 13: Traffic Signs, Markings and Studs

    5 In addition to the ballotini included in the mix, an additional quantity of glass beads shall be
    sprayed on to the hot thermoplastic line at the time of application. The rate of application
    2
    shall be at the rate of about 0.5 kg/m .

    6 The thermoplastic material shall be applied in intermittent or continuous lines of thickness


    1.5 mm 0.3 mm.

    7 For special lettering, arrows or symbols the material shall be applied by hand methods.

    8 The finished lines shall be free from raggedness at all edges and be true in place with the
    road surface.

    9 The upper surface shall be level, uniform and free from streaks, blisters, lumps and other
    defects.

    l .
    .l.
    13.3.4 Performance Requirements and Testing

    rw
    1 The thermoplastic material shall meet the requirements of Table 13.4:

    Table 13.4
    ta
    Properties of Thermoplastic Material
    qa
    Property Minimum Maximum
    3
    Density, g/cm 2.0 approx. -
    as

    Open flashpoint C 230 -


    Softening point (ring and ball BS 2000 Part 58), C 95 105
    se

    Luminance 65 -
    Luminance (Yellow) 45 -
    er

    Flow resistance No Slump -


    Flow resistance after 48 h at 40 C - 25
    ov

    Abrasive wear 9/100 revs - 0.3


    Skid resistance 45 -
    it o

    2 Testing of thermoplastic material shall be as described below. All specimens shall be


    et

    prepared by carefully heating a representative sample to a temperature of (softening point +


    m

    50 C) whilst stirring thoroughly to avoid segregation. The molten material shall be used
    without delay.

    3 Heat Stability Luminance Test: The material shall be cast on to a suitable flat, glossy surface
    coated with a colourless release agent to give a slab 100 mm square by 3 mm thick. The
    luminance of the cast face, with reference to that of a block of magnesium oxide (luminance
    factor l00) shall be measured with the sample illuminated by a tungsten light source at an
    angle of 45 viewed at right angles by a selenium barrier layer photoelectric cell.

    4 Flow Resistance Test: The material shall be cast into a conical mould having an apex angle
    of 60 and a vertical height of 100 mm. After cooling and setting for 24 h the cone shall be
    removed from the mould, placed on a flat level surface and maintained at a temperature of
    23 C 2 C for 48 h.
    QCS 2014 Section 06: Road Works Page 14
    Part 13: Traffic Signs, Markings and Studs

    5 Impact Test: A 3 mm thick coating of material shall be prepared as a screed on a Monel alloy
    panel 1.25 mm thick, previously coated with rubberised bitumen emulsion. The impact
    instrument, a 4.7 kg weight, shall be dropped vertically through 250 mm on to the surface of
    the panel, striking the surface with a hemispherical indentor of radius of 6 mm. The panel
    shall be retained by a metal block drilled to allow the indentor to strike the panel, with the
    depth of indentation limited to 2 mm. Five panels shall be tested and no fracture shall result
    from impact. A crack not longer than 2 mm will be accepted provided there is a smooth
    indentation in the material.

    6 Abrasive Test: A 3 mm thick coating of material shall be screeded on to a Monel alloy panel
    and subject to wet (water lubricated) abrasion at 23 C on a Taber Model 503 standard
    abrasion tester using H-22 Calibrade wheels, refaced between tests. The loss in weight after

    .
    two successive tests of 100 revolutions shall be recorded and the average taken as the

    l
    .l.
    abrasive wear. The abrasive wear shall be less than the figure in Table 13.4.

    rw
    7 Skid Resistance: A 100 mm wide line of material 1.5 mm thick shall be screeded on to a flat,
    level base for a minimum length of 800 mm. After cooling to ambient temperature the skid

    ta
    resistance shall be measured using the TRRL Portable Tester as described in Road Note 27.
    Measurements shall be made on different parts of the specimen, corrected for temperature
    qa
    effects, and the average recorded.
    as

    13.3.5 Protection of Pavement Markings


    se

    1 The Contractor shall control the traffic in such a manner as to protect the freshly marked
    surface from damage. The traffic control shall be so arranged as to give minimum
    er

    interference to the travelling public. Signs, barricades, flagmen and control devices shall be
    supplied by the Contractor and a system of spaced warning flags or blocks shall be used to
    ov

    protect the fresh marking until it has dried as required. Any lines, stripes or markings which
    become blurred or smeared by the traffic shall be corrected by the Contractor.
    o

    13.4 TEMPORARY ROAD MARKING


    it
    et

    13.4.1 ROAD MARKING PAINT


    m

    1 The use of road marking paint shall be restricted to traffic diversions or for other uses as
    directed by the Engineer.

    2 Road marking paint shall be by an approved manufacturer. It shall be suitable for applying by
    brush or mechanical means to cement, concrete or bituminous pavement to give a
    chemically stable film of uniform thickness and shall be chlorinated rubber, one pack epoxy
    or alkyd based.

    3 White paint shall contain not less than 6 % by mass of titanium dioxide as a pigment,
    conforming to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1

    4 Yellow paint shall be standard colour BS 381C No. 355, except where an alternative shade
    has been designated, and contain not less than 6 % by mass of a suitable yellow pigment.
    QCS 2014 Section 06: Road Works Page 15
    Part 13: Traffic Signs, Markings and Studs

    5 The paint shall be supplied fresh and ready for use in sealed containers and stored in
    accordance with the manufacturer's instructions. The paint shall be applied without the use of
    thinners or other additives.

    6 Paint shall be applied at a covering rate recommended by the manufacturer and approved by
    the Engineer.

    7 Where markings are to be reflectorised with ballotini it shall be sprayed uniformly on to the
    2
    wet paint film at the rate of 400-500 g/m . Ballotini shall be graded to comply with the
    requirements of BS 6088.

    8 Road marking materials shall only be applied to surfaces which are clean and dry. Markings
    shall not be ragged at their edges and shall be uniform and free from streaks. Carriageway
    lane and edge lines shall be laid by approved mechanical means to a regular alignment.

    l .
    13.4.2 ADHESIVE ROAD MARKING STRIP

    .l.
    rw
    1 For temporary diversions the use of self adhesive proprietary marking strips will be permitted.

    2 Self adhesive proprietary road marking strips shall be of the details and dimensions shown
    on the drawings.
    ta
    qa
    3 The strips shall have a metallic backing that peels of and shall have reflective properties by
    the incorporation of ballotini.
    as

    13.4.3 REMOVAL OF ROAD MARKINGS


    se

    1 Where it is necessary to remove existing thermoplastic road markings the material shall be
    completely removed by sand blasting or other abrasive methods.
    er
    ov

    2 Care shall be taken to avoid damaging the wearing course surface during this operation.

    3 Any damage caused to the wearing course shall be made good to the satisfaction of the
    o

    engineer.
    it
    et

    4 The painting over of old road markings with black paint shall not be permitted.
    m

    13.5 REFLECTIVE STUDS

    13.5.1 General

    1 Reflective road markers shall be smooth, pressure moulded aluminium alloy, complying with
    BS 1490 with lenses to meet the performance requirements of this specification. They shall
    be capable of withstanding the climatic conditions of Qatar and be maintained free. A
    performance guarantee of five years is required.

    2 The Road stud shall measure 130 mm x 115 mm x 25 mm when seated on the road surface.
    Exact size of the road stud shall be as designated.

    3 The shaft shall be "Anti-Twist/Hot-Tite", 76 mm long.

    4 The slope of the reflecting face shall be 20.


    QCS 2014 Section 06: Road Works Page 16
    Part 13: Traffic Signs, Markings and Studs

    5 The enveloping profile of the head of road studs shall be smooth and the studs shall not
    present any sharp edges to traffic.

    6 The body of the stud shall be constructed in one integral part.

    7 The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel
    flats, the flats on the alternative ribs being at 90 to each other to prevent rotation of the stud
    when located in the road surface.

    8 The studs shall be constructed in aluminium alloy to BS 1490 to provide a robust and durable
    location for the lenses. The alloy shall have the characteristics listed in Table 13.5.

    Table 13.5
    Composition of Alloy for Road Studs

    l .
    Composition Minimum (%) Maximum (%)

    .l.
    Copper - 0.1

    rw
    Silicon - 13.0
    Iron - 0.6
    Manganese - 0.5
    Nickel -
    ta 0.1
    qa
    Zinc - 0.1
    Lead - 0.1
    Tin - 0.1
    as

    Titanium - 0.5
    Aluminium - Remainder
    se

    The Contractor shall submit mill certificates for the material showing the actual composition.
    er

    9 Reflective studs mechanical and physical properties shall comply with the Table 13.6
    ov

    requirements:
    Table 13.6
    Mechanical and Physical Properties of Reflective Studs
    it o

    Mechanical Properties Minimum


    et

    2
    0.2 proof stress test, N/m 120
    m

    2
    Tensile Strength, N/mm . 280
    Elongation, mm 2-5

    Physical Properties Minimum

    Specific gravity 2.65


    Method of Casting Injection
    Corrosion rating Excellent
    Brinell hardness number 55 - 60

    13.5.2 Reflectors

    1 The reflectors shall be rectangular in shape. The rectangular reflective unit shall be firmly
    located into a recess within the body of the stud such that the reflective face is established at
    the correct orientation. A sample of the proposed reflective studs shall be submitted for the
    Engineers approval.
    QCS 2014 Section 06: Road Works Page 17
    Part 13: Traffic Signs, Markings and Studs

    2 The Optical Performance (specific intensity) of each crystal reflecting surface shall not be
    less than the values listed in Table 13.7.
    Table 13.7
    Optical Performance of Reflectors
    Observation Angle, 0.3 0.5 1.0 2.0
    Entrance Angle, 5 10 10 15
    Specific Intensity 160 100 27 3
    Specific Intensity 120 72 20 2

    3 For yellow reflectors the specific intensity shall be 50% of the value for crystal. For red and
    green reflectors the specific intensity shall be 20% of the value for crystal.

    l .
    .l.
    4 The colour limits of the reflector(s) when illuminated by CIE standard illumination A, with an
    entrance angle V= 0 , H= 5 L or R, and an observation angle of 0.3 shall comply with the

    rw
    requirements given in the following paragraphs.

    5
    ta
    White (uncoloured) reflectors shall not produce a selective reflection; that is to say, the
    qa
    trichromatic co-ordinates X and Y of the standard illuminant A used to illuminate the reflector
    shall undergo a change of more than 0.91 after reflection by the reflector.
    as

    6 Red reflectors shall have chromaticity co-ordinates which lie within the area formed by the
    straight lines defined by the following pairs of points, 1 and 2, 2 and 3, the spectrum locus,
    se

    and the line joint the ends of the spectrum locus:


    Co-ordinate Point 1 Point 2 Point 3
    er

    X 0.665 0.657 0.730


    Y 0.335 0.335 0.262
    ov

    7 Amber reflector shall have chromaticity co-ordinates which lie within the area formed by the
    straight lines defined by the following pairs of points, 1 and 2, 2 and 3, 3 and 4, and the
    o

    spectrum locus:-
    it

    Co-ordinates Point 1 Point 2 Point 3 Point 4


    et

    X 0.330 0.228 0.321 0.302


    Y 0.385 0.351 0.493 0.692
    m

    8 Compliance with the colorimetric requirements shall normally be verified by means of a visual
    comparison test. If any doubt remains after this test, compliance shall be verified by the
    determination of the trichromatic co-ordinates as defined in the proceedings of the 1951
    meeting of the International Commission (CIE).

    13.5.3 Reflectivity

    1 A sample of the road stud shall be submitted by the Contractor and relevant technical
    information, catalogues supplied by the manufacturers shall accompany the sample.

    2 The reflectivity of the stud when new shall well exceed minimum standard as laid down in BS
    873 and meet typical values as shown below:
    QCS 2014 Section 06: Road Works Page 18
    Part 13: Traffic Signs, Markings and Studs

    Table 13.8
    White Reflectors Tested to BS 873
    CIL Value CIL Value
    (mod/1x) (mod/1x)
    Orientation
    Typical Minimum

    Observation angle 2 Entrance Angle 15 L and 15 R. 5-7.5 2


    Observation Angle 2 Entrance Angle 10 L and 10 R 26.5-30 10
    Observation Angle 0.5 Entrance Angle 10 L and 10 R 59-93 15
    Observation Angle 0.3 Entrance Angle 5 L and 5 R 100-190 20

    Table 13.9
    Amber Reflectors Tested to BS 873

    l .
    .l.
    CIL Value CIL Value
    (mod/1x) (mod/1x)

    rw
    Orientation
    Typical Minimum
    Observation angle 2 Entrance Angle 15 L and 15 R.
    ta
    Observation Angle 1 Entrance Angle 10 L and 10 R.
    3-4
    10-20
    1.0
    5.0
    qa
    Observation Angle 0.5 Entrance Angle 10 L and 10 R. 20-50 7.0
    Observation Angle 0.3 Entrance Angle 5 L and 5 R. 30-90 10.0
    as
    se

    Table 13.10
    er

    Red Reflectors Tested to BS 873


    CIL Value CIL Value
    ov

    (mod/1x) (mod/1x)
    Orientation
    Typical Minimum
    o

    Observation angle 2 Entrance Angle 15 L and 15 R 1.5-2.0 2.0


    it

    Observation Angle 1 Entrance Angle 10 L and 10 R


    et

    4.5-7 10.0
    Observation Angle 0.5 Entrance Angle 10 L and 10 R 10-20 15.0
    m

    Observation Angle 0.3 Entrance Angle 5 L and 5 R. 16-35 20.0

    13.5.4 Installation of Reflective Studs

    1 Reflective studs shall be installed and anchored to the pavement as follows:

    (a) Drill a hole into the asphalt pavement to the dimensions recommended by the
    manufacturer. Ensure that the hole is free of dust and also the pavement surface
    within a radius of 200 mm of the hole is free from debris and dust.

    (b) Fill the hole to overflow with the two part epoxy adhesive of the type specified in clause
    10.6.2.
    QCS 2014 Section 06: Road Works Page 19
    Part 13: Traffic Signs, Markings and Studs

    (c) Immediately after pouring the grout, the road stud shall be inserted into the hole and
    the reflective face aligned to the oncoming traffic. The road stud shall be firmly
    embedded into the ground ensuring a good bed of grouting compound under the road
    stud and solid fixing. Protect the installed marker until the epoxy adhesive has
    completely set.
    (d) Clean off any surplus grouting and protect the road stud from traffic for approximately
    60 minutes.

    13.6 NON-REFLECTIVE STUDS

    13.6.1 General

    1 Non-reflective road studs shall be ceramic and of approximately 100 mm diameter at the
    base, the studs shall consist of a heat-fired, vitreous ceramic base and a heat fired opaque

    .
    smooth matte surface.

    l
    .l.
    2 The colour of the studs shall be white unless otherwise designated. The base of the stud

    rw
    shall have a rough surface to ensure a good bond to the road.

    3
    ta
    The adhesive used for the installation of non-reflective ceramic studs shall be a two part
    epoxy or other material recommended by the manufacturers and tested under the climatic
    qa
    and traffic conditions prevalent in Qatar.

    4 The non-reflective ceramic studs shall conform to the dimensions and shapes shown on the
    as

    drawings and shall be installed at the location indicated on the drawings or where designated
    by the Engineer.
    se

    5 The studs shall be ceramic manufactured and shall consist of a heat-fired, opaque, glazed
    er

    surface. The glazed surface shall not be present on the bottom of the studs which will be
    cemented to the road surface. The outer surface of the studs shall be smooth except for
    ov

    purpose of identification, and all edges exposed to traffic must be convex and the radius
    nearest the edge may be less. Any change in curvature shall be gradual. The bottom
    o

    surface of the marker shall be of a roughness comparable to at least that of a fine grade of
    it

    sandpaper, and shall be substantially free form gloss or substance that may reduce its bond
    et

    to the adhesive.
    m

    6 The body of the marker shall be white.

    7 Brightness will be measured with equipment conforming ASTM E97 using a Brightness
    Standard of 75%. The minimum weight of the marker shall be 125 grams.

    8 A random sample of 5 buttons shall be subjected to the compressive load test. The average
    compressive strength of the 5 buttons shall not be less than 680 kg and no individual button
    shall have a compressive strength less than 544 kg. The button shall be centered base
    down, over the open end of a vertically positioned hollow metal cylinder. The cylinder shall
    be 25.4 mm high, with an internal diameter of 76.2 mm and a wall thickness of 6.4mm. A
    load necessary to break the button shall be at speed of 2.5 mm per minute to the top of the
    button. In the event that the bottom of the marker is dimpled, a 2 mm layer of wood shall
    insert between the base of the maker and the hollow cylinder. Should any of the samples
    tested for strength fail to comply with this specification, 10 additional samples will be tested.
    The failure of any one of the additional samples shall be cause for rejection of the entire lot or
    shipment represented by the samples.
    QCS 2014 Section 06: Road Works Page 20
    Part 13: Traffic Signs, Markings and Studs

    13.6.2 Materials and Manufacture

    1 The studs shall be produced from a combination of intimately mixed clays, shales, flints,
    feldspars or other inorganic material which will ensure the required properties are met. All
    studs shall be thoroughly and evenly matured and free from defects which affect appearance
    or serviceability.

    2 The studs shall be of uniform composition and free from surface irregularities cracks,
    chipping, peeling spoiling, crazing and any other physical damage. The studs shall be precast
    in the form of a single based spheroidal segment terminating in a rounded or squared
    shoulder.

    3 The height of the studs above road level shall be between 18 mm and 20 mm.

    .
    4 Compliance of the studs with respect to appearance, shape, dimensions and compressive

    l
    .l.
    strength shall be determined in accordance with CML Method 14-97. In particular, they shall
    exhibit an average compressive load at failure for each sample of 5 studs of not less than

    rw
    680 kg and no individual value shall be less than 544 kg. Furthermore, the water absorption
    shall not exceed 1.0% when tested in accordance with ASTM C373. And the glazed surface
    of the stud shall not craze, spell, or peel when subjected to one cycle of the Autoclave test at
    250 psi when tested in accordance with ASTM C424.
    ta
    qa
    5 The adhesive for reflective studs and non-reflective studs shall be a two component epoxy.
    Each component shall be supplied in separate clearly marked containers and the time of use
    as

    the contents of the two parts shall be thoroughly redispersed by mixing. Only complete
    containers of each part shall be used and these shall be mixed thoroughly until a uniform
    se

    colour is achieved with no streaks of individual colours. The blend of the two components of
    epoxy thoroughly mixed together shall meet Table 13.11.
    er
    ov

    Table 13.11
    Specification for Epoxy Adhesive
    o

    Property Value
    it
    et

    Gel time 5 to 30 minutes


    m

    Minimum Tensile strength of 1.6 mm film between steel blocks cured 2


    7 N/mm
    24 h at 21 C tested at 21 C

    Shore hardness on 24 h sample at 21C 70 to 80

    Shore hardness on 24 h sample at 49 C 30 minimum

    Deformation temperature, C 49 minimum

    6 The Contractor shall submit recent test results that confirm the above properties of the
    supplied adhesive are met.

    7 The epoxy shall be used strictly in accordance with the manufacturers recommendation for
    storage preparation, mixing and application. Any differences from the manufacturers
    recommendations and this specification shall be referred to the Engineer.
    QCS 2014 Section 06: Road Works Page 21
    Part 13: Traffic Signs, Markings and Studs

    8 The final colour of the epoxy adhesive shall be uniform grey unless designated otherwise.

    13.6.3 Installation

    1 All sand, dirt and extraneous material shall be removed from the mark location and the
    surface cleaned and abraded. Cleaning shall be by compressed air. In the case of adhering
    material the application of heat or sand blasting will be required.

    2 The surface shall be completely dry for the application of the adhesive.

    3 The base of the supplied stud shall be free of any wax or grease from the manufacturing
    process. Any such wax or grease shall be sanded off the bottom of the marker.

    4 The adhesive components shall be stored at the temperature recommended by the


    manufacturer both before use and during application. The two components of the adhesive

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    shall be added to each other just before use, any unused mixed adhesive shall be discarded

    .l.
    when catallic actions cause stiffening and reduction of workability or balls of gelled resin

    rw
    formed in the container.

    5 The mixed adhesive shall be applied to the prepared pavement area to be covered by the

    ta
    marker and the stud pressed onto the adhesive so as to squeeze out a small bead of
    adhesive around the periphery of the stud.
    qa
    6 The Contractor shall carry out a trial outside of the permanent works to establish the
    as

    approximate amount of adhesive required per marker and application on the works shall be
    carried out to this quantity.
    se

    7 The studs shall not be fixed to the pavement where asphalt has been laid within the last 14
    days unless otherwise directed by the Engineer. The studs shall be spaced and aligned as
    er

    designated or as per the Qatar Traffic Control Manual. The tolerance for placing shall be not
    ov

    more than 10 mm.

    8 Where studs are to be applied to pavement where the road is to be opened to public traffic
    o

    shortly after placing, the preheating of the roadway surface to permit a rapid set is permitted.
    it

    In such cases, the procedure followed shall be as recommended by the supplier of the epoxy
    et

    adhesive and as approved by the Engineer.


    m

    9 On roadway sections that are not opened to public traffic no preheating of the studs or road
    2
    surface is required as long as the required bond strength of 12 kg/cm can be achieved in
    less than 3 h.

    END OF PART
    QCS 2014 Section 06: Road Works Page 1
    Part 14: Works in Relation to Services

    14 WORKS IN RELATION TO SERVICES ........................................................ 2

    14.1 GENERAL ...................................................................................................... 2


    14.1.1 Scope 2
    14.1.2 References 2
    14.1.3 Submittals 2
    14.1.4 Notification to Service Authorities & Statutory Bodies 3
    14.2 SERVICES GENERALLY .............................................................................. 3
    14.2.1 General 3
    14.2.2 Safety 4
    14.2.3 Marking Services 4
    14.2.4 Location of Existing Services 5

    .
    14.2.5 Protection of Services 5

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    14.2.6 Relocation of Services 6

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    14.2.7 Services Ducts 7
    14.2.8 Excavation for Ducts 7
    14.2.9 Bedding and Laying of Ducts 8
    14.3 ta
    PARTICULAR REQUIREMENTS .................................................................. 8
    qa
    14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks
    Affairs, QGEWC (ENA) 8
    as

    14.3.2 Qatar General Electricity and Water Corporation, Water Networks


    Affairs, QGEWC (WNA) 10
    se

    14.3.3 Telecom Provider 10


    14.3.4 Qatar Petroleum (QP) and Qatar Gas 12
    er

    14.3.5 PWA, Storm water and Groundwater 13


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    et
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    QCS 2014 Section 06: Road Works Page 2
    Part 14: Works in Relation to Services

    14 WORKS IN RELATION TO SERVICES


    14.1 GENERAL

    14.1.1 Scope

    1 This Part includes the provision of new services and the seeking, protection, diversion and
    relocation of the existing services for the following service authorities:
    Qatar General Electricity & Water Corporation (QGEWC)
    Telecom Provider
    Qatar Petroleum (QP) and Qatar Gas
    Public Works Authority (PWA)
    Urban Planning and Development Authority (UPDA)

    .
    Local Municipality

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    2 Related Sections and Parts:

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    This Section Part 1 General
    Part 3 Earthworks
    Part 17 Road Drainage
    ta
    qa
    Section 1 General
    Section 5 Concrete
    Section 20 Drainage Works For Buildings
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    14.1.2 References
    se

    1 The following standards and reference documents are referred to in this Part:
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    BS 1377......................Methods of tests for soils for civil engineering purposes


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    BS 2484......................Straight concrete clayware cable covers


    BS 2782......................Methods of testing plastics.
    it o

    14.1.3 Submittals
    et

    1 The Contractor shall prepare and submit records and sketches showing position, levels and
    m

    types of each existing service including manholes, joint boxes, inspection chambers and
    connections. These records shall be maintained in the form of a daily diary.

    2 The Contractor shall prepare and submit shop drawings for utility protection work and obtain
    the approval of the appropriate Authority before beginning construction.

    3 Samples of proposed ducts shall be submitted to the Engineer for his approval beforehand.

    4 The Contractor shall prepare and maintain up-to-date drawings for each service authority
    giving details of each duct laid including precise location, level, number and type, and these
    drawings are to be submitted to the Engineer.

    5 The Contractor shall keep accurate records of the arrangement, positions and details of all
    works constructed by him as Record Drawings. The details, format, extent and procedures
    for the preparation and submission of the record drawings shall be in accordance with
    Section 1.
    QCS 2014 Section 06: Road Works Page 3
    Part 14: Works in Relation to Services

    14.1.4 Notification to Service Authorities & Statutory Bodies

    1 All works in relation to services shall be carried out by a contractor or subcontractor


    prequalified and approved by the concerned service authority. Proof of such approval shall be
    required in writing before the start of Works on the Site. The name of any subcontractor to be
    used shall be as designated.

    2 No work concerning services will be started without having first informed and obtained
    approval of the concerned service authorities. Before opening the ground for any purpose,
    the Contractor must notify all concerned parties by issue of formal "Notice of Intent" and must
    obtain information by formal notice regarding the location of all services. The complete
    responsibility for obtaining this information rests with the Contractor. "Notices of Intent" shall
    be circulated to all concerned parties including those listed in Clause 11.1.1:
    Qatar General Electricity & Water Corporation (QGEWC)

    .
    Telecom Provider

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    Qatar Petroleum (QP) and Qatar Gas
    Public Works Authority (PWA)

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    Urban Planning and Development Authority (UPDA)
    Local Municipality
    3
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    Prior to commencing any work on excavation in a roadway the Contractor shall obtain the
    qa
    approval of the Traffic Police. All excavations in a roadway shall be carried out in accordance
    with PWA road opening procedures.
    as

    4 Drawings and notices shall be sent in duplicate one of which shall be retained by the
    addressee and the other returned to the sender duly marked to show underground services.
    se

    "Notice of Intent" will be given 14 days in advance of starting the proposed Works. In the
    event that the work is not started within eight weeks of the date of the "Notice of Intent", it will
    er

    be deemed to have lapsed. A further Notice of Intent will then be submitted. The Contractor
    shall furnish copies of the above Notices of Intent to the Engineer.
    ov

    5 The Contractor's attention is particularly drawn to the procedures to be followed concerning


    existing services and service diversions laid down in all current administrative orders of the
    o

    service authorities.
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    et

    14.2 SERVICES GENERALLY


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    14.2.1 General

    1 The Contractor shall acquaint himself with the position of all existing services and shall obtain
    clearance from the concerned service authority before commencing any work in a particular
    area. Written evidence of such clearance shall be provided to the Engineer by the Contractor.

    2 The position, types of ducts, pipes, cables, manholes and related structures are designated,
    but the final location will be determined on site by the Contractor and submitted to the
    Engineer for approval after having consulted with the concerned service authorities.

    3 All concrete works shall conform to the requirements of Section 5.

    4 The Contractor will be fully responsible for ensuring observance of the requirements of this
    clause by his subcontractors.
    QCS 2014 Section 06: Road Works Page 4
    Part 14: Works in Relation to Services

    5 Where any utility or service works are to be constructed under a separate contract by the
    Engineer within the Site and concurrent with the execution of the Works, the Contractor shall
    co-operate with the other contractor and shall co-ordinate his construction operations to avoid
    interference with the other contractor's operations.

    6 Any public or private service for water, electricity, drainage, or other utility, affected by the
    Works shall not be interrupted without the written permission of the Engineer. Such
    permission will be withheld until suitable approved permanent or temporary alternative
    services have been provided by the Contractor or by the owner of the utility or his agents.

    7 For temporary traffic diversions as may be required for the construction of road crossings, full
    liaison with the Municipality and Police shall be required as well as compliance with the
    requirements of the PWA road opening procedures.

    8 The Contractor shall be responsible for following each service authorities inspection and

    l .
    testing procedures.

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    rw
    9 The Contractor shall be responsible for liaison with each service authority to obtain their
    approval for the completion of the works.

    14.2.2 Safety
    ta
    qa
    1 The Contractor shall be responsible for public safety during execution of work. He shall take
    all measures, including, where necessary, the provision of ropes, picket fences, and other
    as

    temporary barriers on the sides of trenches and excavations with warning lights.
    se

    2 The Contractor shall arrange for night watchman and any other measures required to ensure
    the safety of the public.
    er

    3 The Contractor will be held responsible for any damage to property or injury to persons due
    ov

    to his negligence. Any instruction from the Engineer concerning the safety aspects of the
    work must be carried out immediately, but the Contractor shall remain responsible for the
    adequacy of the safety measures.
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    4 The Contractor shall take into account the current laws regarding the safety of service lines,
    et

    together with any amendment or additions thereto. The Contractor shall be responsible for
    locating or verifying the location of existing services, liaison with the various service
    m

    authorities and complying with the above.

    14.2.3 Marking Services

    1 All services shall be provided with continuous warning tapes with the requirements of the
    following paragraphs.

    2 The Contractor shall install approved warning tapes during backfilling work over buried pipes,
    cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for
    identification according to the requirements of the concerned service authority.

    3 Warning tape shall be approved high quality, acid and alkali-resistant polyethylene film
    250 mm wide, and with a minimum thickness of 150 microns. Tape shall have a minimum
    tensile strength of 125 kg/cm2 longitudinally and 105 kg/cm2 laterally with an elongation
    factor of 350 %.
    QCS 2014 Section 06: Road Works Page 5
    Part 14: Works in Relation to Services

    4 Tape shall be printed with 50 mm high black lettering, alternatively in Arabic and English. The
    complete wordings shall be repeated every 2 m along the tape. The colours shall be vivid,
    glossy and permanent with a life expectancy of 40 years.

    5 Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape
    relating to the top of service shall be in accordance with the requirements of the concerned
    service authority.

    6 Warning tapes over non-metallic services shall be backed with aluminium foil to facilitate
    detection.

    14.2.4 Location of Existing Services

    1 The positions of all designated public and privately owned services have been based on the

    .
    records of various service authorities and must be regarded as approximate.

    l
    .l.
    2 The positions designated for existing services are for informational purposes only and do not

    rw
    necessarily show exact locations, depths, spacings, or the presence and location of smaller
    services such as house connections which are not normally designated.

    3 ta
    The Contractor shall verify this information and satisfy himself as to the exact nature and
    qa
    position of all such apparatus. The Engineer does not guarantee the accuracy of the
    designated information, and no warranty is given or implied.
    as

    4 The Contractor shall verify the position of services by digging trial trenches and pits. If ducts,
    pipes, cables and manholes which are not designated are found, the Engineer and the
    se

    concerned service authority shall be informed as soon as possible. The concerned service
    authority will then instruct on the action to be taken, if any.
    er

    5 The Contractor shall excavate by hand, take trial pits at regular distances and also at all road
    ov

    intersections to locate existing services, their number, depth and route direction. As these
    services are located the Contractor shall prepare record drawings indicating the
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    aforementioned information which shall be submitted to the Engineer.


    it
    et

    14.2.5 Protection of Services


    m

    1 The Contractor shall take any and all measures reasonably required by any public or
    concerned service authority for the support and full protection of all mains, pipes, cables and
    other apparatus during the progress of the Works, and shall construct and provide to the
    satisfaction of the concerned service authority, all works necessary for the prevention of
    damage or interruption of services.

    2 The protection of the existing services shall be carried out before the earth work starts in the
    vicinity of the services to be protected.

    3 If some services have already been protected by the various Departments, no protection will
    be carried out under this Contract, but such protection can be extended or upgraded as
    instructed by the Engineer on Site after having consulted with the concerned service
    authority.
    QCS 2014 Section 06: Road Works Page 6
    Part 14: Works in Relation to Services

    4 If in the execution of the Works, by reason of any subsidence caused by, or any act of
    neglect or default of the Contractor, any damage to any apparatus or any interruption of, or
    delay to, the provision of any service is caused, the Contractor shall report it to the Engineer
    immediately and bear and pay the cost reasonably incurred by the service authority
    concerned in making good such damage and shall make full compensation to the authority
    for any loss, sustained by reason of such interruption or delay.

    5 All protected services, existing ducts found or newly laid ducts shall be marked with markers
    of approved of size and type as designated. The location of markers shall be as designated.
    No asphalt course will be laid unless the ends of the ducts or protected services have been
    exposed and marked with markers.

    6 The Contractor shall, at all times during the progress of the works, afford facilities to properly
    accredited agents of any concerned service authority for access to all or any of their
    apparatus situated in or under the site, as may be necessary for inspecting, reporting,

    l .
    maintaining, removing, renewing or altering such apparatus in connection with the

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    construction of the Works or any other purpose whatsoever.

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    14.2.6 Relocation of Services

    1
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    The Contractor shall relocate certain utilities to service reservation areas as designated. This
    qa
    work may only include constructing necessary protective housing such as box culverts, slabs,
    and concrete encased sleeves in the service reservation areas for utility lines to be relocated.
    Or this work may include necessary protective housing as described above and, in addition,
    as

    the relocation of specific utility lines to the service reservation areas.


    se

    2 In both cases the Contractor shall complete the necessary survey to establish the lines and
    levels, prepare shop drawings and submit them to the Engineer for his review. The
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    Contractor shall obtain approval from the concerned service authority before commencing
    this work.
    ov

    3 After existing services, according to the Engineer's instruction, have been exposed and if
    according to the opinion of the Engineer and after approval of the concerned service
    o

    authorities it is found necessary to proceed with the lowering or diversion thereof, the
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    Contractor shall proceed with the relevant excavation in co-ordination with the said
    et

    authorities.
    m

    4 The Contractor shall maintain records of such excavation in a form acceptable to the
    Engineer. Two copies of such records shall be submitted to the Engineer on a weekly basis
    or as agreed with by the Engineer.

    5 All materials removed shall be disposed of by the Contractor as designated.

    6 When directed by the Engineer, all such excavations shall be backfilled with suitable material,
    placed and compacted as designated.

    7 The Contractor shall place fill material and compact with care to avoid damage to the existing
    services. The Contractor shall be responsible for any and all damages caused by his
    construction operations.

    8 The works relevant to the lowering of existing services will be started as soon as, according
    to the Engineer, all the necessary precautions have been taken to prevent any injury to
    person or damage to property or services.
    QCS 2014 Section 06: Road Works Page 7
    Part 14: Works in Relation to Services

    9 The excavation for lowering existing services shall be performed by hand down to the
    elevation indicated by the Engineer and the concerned service authority.

    10 At all times the Contractor shall provide and maintain access to the adjoining properties to
    the satisfaction of the Engineer.

    14.2.7 Services Ducts

    1 Service ducts shall be provided as designated so that future services can pass through them
    without disturbing road construction.

    2 The Contractor shall supply, unless otherwise designated, and install all the necessary
    service ducts required for the project. The duct material shall be as designated.

    3 Road crossing ducts shall extend beyond the road or shoulder line at each side of the road

    l .
    as designated.

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    4 To prevent earth blocking the ducts, the openings at both ends are to be protected with
    appropriate blanking caps.

    5
    ta
    In general, all duct laying work is subject to the approval of the Engineer and any particular
    requirements of the concerned service authority.
    qa
    6 The Contractor shall after completing each duct, make the necessary arrangements with the
    as

    service authority for testing and acceptance of the work. As a minimum this shall involve the
    verification of the duct by rodding or pulling through a mandrel.
    se

    14.2.8 Excavation for Ducts


    er

    1 The trench shall be excavated to the designated width and depth.


    ov

    2 When appropriate, the excavation for the road crossing and laying of ducts, concreting and
    related work shall only be carried out on half the width of the road at one time, the other half
    o

    being left available for traffic. In this case the necessary traffic warning signs on self-
    it

    supporting tripods or cones shall be provided well ahead of the duct crossing work and all
    et

    care and attention exercised to avoid risk of traffic accidents during preparation and
    execution of the work.
    m

    3 All trenches and other excavation shall be maintained in a dry condition and the Contractor
    shall arrange a suitable dewatering system for any dewatering involved, in agreement with
    the Engineer, to keep the working place clean and dry.

    4 The sides of pits and trenches shall be vertical and adequately supported at all times.
    Excavations may if considered necessary be battered with a safe slope, but only with the
    Engineer's written permission.

    5 Where ducts are laid under any area of the road construction, the bottom of the excavation
    shall be completed to a density of 95 % of the maximum dry density, as determined by BS
    1377 Test 13 or as otherwise approved by the Engineer.

    6 Excavated material shall, if found unsuitable as defined in Part 3 of this Section, be disposed
    of to an approved tip and replaced with suitable material. All surplus suitable excavated
    material shall be used in road construction or disposed of in an approved manner.
    QCS 2014 Section 06: Road Works Page 8
    Part 14: Works in Relation to Services

    7 Where split ducts are required for existing services crossing the Works, hand excavation
    shall be carefully undertaken until the position of the service to be protected is fully exposed.

    14.2.9 Bedding and Laying of Ducts

    1 As soon as possible after trench excavation, ducts of the required diameter shall be laid and
    jointed as designated and in accordance with the manufacturer's instructions.

    2 Ducts shall be laid to the designated lines and levels with the required depth of cover. Where
    the designated minimum cover cannot be achieved, or as otherwise directed by the Engineer,
    they shall be bedded and surrounded with 150 mm of grade 20 concrete.

    3 Unless surrounded in concrete, ducts shall be bedded on a 150 mm thick layer of well graded
    sand of maximum particle size 5mm and fully surrounded with sand to a depth of 150 mm

    l .
    above the duct barrel, well packed and tamped. Filling with suitable material above this level

    .l.
    shall be free from large stones. For multiple ducts, the spaces between ducts are to be filled

    rw
    with compacted sand and the ducts surrounded to a depth of l50 mm above the uppermost
    layer. Trench backfill shall be compacted to the designated requirements.

    4
    ta
    Ducts shall be cut by the Contractor as necessary only at right angles to their length using a
    qa
    saw in a simple cutting guide. The inside cut edges Shall be thoroughly rounded off or
    dressed before installation to prevent damage to cables drawn through the ducts.
    as

    5 In kerbed areas of new roadway duct markers shall be used. Duct marker shall be of
    concrete construction, in-situ or precast depending on the location, as per the designated
    se

    details complete with approved abbreviation cast thereon. The finished product shall be solid
    in appearance, free of segregation, honeycombing broken edges and other defects.
    er

    14.3 PARTICULAR REQUIREMENTS


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    14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC
    o

    (ENA)
    it
    et

    1 All of the works associated with electricity supply shall be carried out in accordance with the
    latest specifications for materials, excavation and backfill, cable laying and jointing, as issued
    m

    by the QGEWC (ENA). Contractors are deemed to be in possession of the latest QGEWC
    (ENA) specifications.

    2 All QGEWC (ENA) MV, HV and EHV works shall be carried out by a Contractor or
    subcontractor prequalified and approved by the QGEWC (ENA). Proof of such approval shall
    be required in writing before the start of Works on the Site, and the name of any
    subcontractor to be used shall be as designated. All cable jointers to be used on the Contract
    shall be required to undertake and pass a trade test conducted by QGEWC (ENA).

    3 The Contractor shall comply with all requirements of the Police Department for marking,
    lighting and protecting excavation. It is the responsibility of the Contractor to ascertain the
    requirements of the Police Department and to comply fully with these requirements.

    4 Where carriageway works and road crossings are performed the Contractor shall provide
    steel plates of sufficient size and quality to permit the safe passage of traffic and the plates
    shall be so placed (and if necessary fixed) to permit reasonable traffic flow.
    QCS 2014 Section 06: Road Works Page 9
    Part 14: Works in Relation to Services

    5 All doorways, gates and entrances shall be kept clear with full access. Where excavations
    impede pedestrian access crossing boards shall be provided. Crossing boards shall be 1250
    mm wide with a handrail on both sides 1 m in height and guard-rails on both sides at
    vehicular and pedestrian access to premises. Ducts will not be installed at entrances to
    premises except on the express instruction of the Engineer.

    6 Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not
    possible, the material shall be removed from site and returned for backfilling on completion of
    cable laying. In cases where the excavated material is not to be used for backfilling trenches
    it must be removed from site on the same day as it is excavated.

    7 QGEWC (ENA) will require to carry out inspections at the following stages:

    (a) Completion of excavations.

    .
    (b) Completion of bedding of trench before cable installation.

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    .l.
    (c) Cable installation.

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    (d) Completion of surround over cables and installation of cable tiles.
    (e) Upon completion of reinstatement.

    8
    ta
    The Contractor must not progress from one stage to the next of the above without the
    qa
    approval of QGEWC (ENA) and the Engineer. The Contractor shall be responsible for
    arranging inspections by QGEWC (ENA) to suit his programme of works.
    as

    9 Where materials are to be supplied by the Contractor, the requirements described in the
    following paragraphs shall apply.
    se

    10 Materials shall be ordered in accordance with the specifications issued by QGEWC (ENA).
    er

    11 For works involving the use of high voltage overhead cables Contractors shall comply with
    ov

    the requirements of QGEWC circular no 6.

    12 Specifications and the details of the proposed supplier shall be submitted to QGEWC (ENA)
    o

    for approval before a firm order being placed.


    it
    et

    13 On delivery of materials to Qatar, QGEWC (ENA) inspectors shall be given the opportunity to
    inspect the materials before their use.
    m

    14 The Contractor shall supply all cables and jointing materials for the works unless expressed
    stated to the contrary in the contract documentation. Cleaning materials, protection tiles,
    warning tape, and other materials shall be supplied by the Contractor.

    15 The Contractor is responsible for all liaison with QGEWC (ENA) in respect of programming
    the installation and commissioning of the complete electrical system. He shall ensure that
    QGEWC (ENA) are at all times kept informed of the current progress of the civil works on the
    Site and that his approved electricity supply subcontractor programs the cable laying works in
    the designated sequence in accordance with the approved programme.

    16 The Contractor shall provide and install concrete cable tiles over all 66 kV cables. The cable
    tiles shall be of the designated size and form. Samples must be provided for approval by
    QGEWC (ENA) and the Engineer, and satisfy a test of impact strength in accordance with BS
    2484.
    QCS 2014 Section 06: Road Works Page 10
    Part 14: Works in Relation to Services

    17 For cables of 132KV and above the measures for protection of the cable shall be as per the
    requirements of QGEWC.

    18 Cable tiles shall be installed over all 11,000 volt cables. Cable tiles shall be manufactured
    from recycled polyethylene or similar with a minimum thickness of 12 mm, length 1 m, width
    (minimum) 24 mm, tensile strength 8.40 N/mm2 as per BS 2782, Method 320 C.

    19 The tiles shall be marked as designated. The cable tiles must be supplied complete with any
    pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC
    (ENA) and the Engineer for approval before use.

    20 The Contractor shall liaise directly with QGEWC (ENA) regarding the removal of existing
    cables and shall not, under any circumstance, commence removal of cables until QGEWC
    (ENA) have verified such apparatus as being redundant.

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    .l.
    21 Removal of cable shall only be carried out in the presence of a QGEWC (ENA) engineer.

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    22 The Contractor shall arrange uplift of empty cable drums from QGEWC (ENA) Stores and
    shall return all recovered cables neatly coiled on the drums provided.

    23 ta
    Ducts are to be supplied by the Contractor. They shall be of high impact resistant PVC of
    qa
    internal diameter 150 mm or 100 mm as designated, minimum wall thickness 3.6 mm (for
    150 mm) or 2.4 mm (for 100 mm). Samples must be provided for approval by the Engineer
    as

    before use.
    se

    14.3.2 Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC
    (WNA)
    er

    1 All of the works associated with water supply shall be carried out in accordance with the
    ov

    latest General Specifications for Main Laying Contracts and Main Laying Materials, as issued
    by the QGEWC (WNA) except as modified in this Part. Contractors are deemed to be in
    possession of the latest specifications.
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    2 All QGEWC (WNA) Works shall be carried out by a Contractor or subcontractor prequalified
    et

    and approved by the QGEWC (WNA). Proof of such approval shall be required in writing
    m

    before the start of Works on the Site and the name of any subcontractor to be used shall be
    as designated.

    3 The supply of the materials required to carry out the Works shall be as designated in the
    contract documents. The Contractor will be responsible for the conveyance of all materials to
    the site of the works.

    14.3.3 Telecom Provider

    1 All Telecom Provider works shall be carried out strictly in accordance with the Telecom
    Provider Standard Specifications Telecom Provider WRK 4001 Underground Duct Laying
    And Associated Works. Contractors are deemed to be in possession of the latest version of
    the specifications.

    2 All Telecom Provider works shall be carried out by a Contractor or subcontractor approved by
    Telecom Provider. Proof of such approval shall be required in writing before the start of
    Works on the Site and the name of any subcontractor to be used shall be as designated.
    QCS 2014 Section 06: Road Works Page 11
    Part 14: Works in Relation to Services

    3 Telecom Provider will supply as 'free issue" all ducts for Road Crossings projects only. Other
    projects will be charged for the ducts. All other materials required for any type of project shall
    be supplied by the Contractor.

    4 Trenches for Telecom Provider ducts through rock fill shall be lined with geotextile, complying
    with the requirements of Part 16, Geosynthetics.

    5 The Telecom Provider specification S. 006 shall be modified as described in the following
    paragraphs.

    6 The Supervising Officer shall mean the Civil/Cable Engineer from Telecom Provider, for the
    purpose of superintending the work, or, where the context permits, the representative of such
    officers.

    7 The concrete quality classes specified in Clause 202 of the Telecom Provider specifications

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    shall be of the comparable classes in Section 5 as designated by the Engineer.

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    8 Clause 105 of Telecom Provider Standard Specifications Telecom Provider WRK 4001
    Underground Duct Laying And Associated Works should be read as:

    105 (a)
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    Backfill materials means earth free from stone or loose earth, compacted in
    two equal layers above the protection dune sand, and shall not leave voids to
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    form a water course.

    Sand bed and surround means dune sand, 75 mm below, above and around
    as

    105 (b)
    the duct.
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    9 The Contractor shall consult Telecom Provider not less than one month before it is proposed
    to commence work to ascertain whether any underground installations will be affected by the
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    proposed works, in which event the Contractor shall make all necessary arrangements with
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    Telecom Provider to safeguard the installations.

    10 The Contractor shall give at least one week's notice in writing to Telecom Provider of the
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    dates upon which it is intended to operate plant or equipment or carry out any work for which
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    permission has been given in writing by Telecom Provider. Such operations of work shall only
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    be carried out in the presence at Telecom Provider unless notice shall be obtained in writing
    from Telecom Provider that they do not require to be present.
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    11 Telecom Provider may require work to be executed on their installations during the period of
    the Contract. The Contractor shall allow access to Telecom Providers Contractor or
    workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
    Telecom Provider and his own activities and when necessary shall amend his programme of
    working to suit all requirements of Telecom Provider in connection with their diversion work
    and shall keep the Engineer informed in writing of all arrangements made.

    12 The Contractor shall locate and mark with suitable posts all Telecom Provider underground
    installations that are within the area of the Works and shall ensure that such markers are
    maintained in their correct positions at all times. The Contractor shall advise Telecom
    Providers agent of any installation not found where designated, or found but not shown or
    found damaged or subsequently damaged.
    QCS 2014 Section 06: Road Works Page 12
    Part 14: Works in Relation to Services

    14.3.4 Qatar Petroleum (QP) and Qatar Gas

    1 All of the works associated with Qatar Petroleum and Qatar Gas shall be carried out in
    accordance with their latest specifications except as modified in this Part. Contractors are
    deemed to be in possession of the latest specifications. Before beginning any work the
    Contractor shall approach Qatar Petroleum and Qatar Gas and obtain a copy of their latest
    specification relating to the Works.

    2 All Qatar Petroleum and Qatar Gas Works shall be carried out by a Contractor or
    subcontractor prequalified and approved by Qatar Petroleum and Qatar Gas. Proof of such
    approval shall be required in writing before the start of Works on the Site and the name of
    any subcontractor to be used shall be as designated.

    3 When working near existing QP Gas/Oil facilities the following conditions shall be adhered to.
    All notices to be given to the Contractor shall be in writing and delivered by hand.

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    4 A permit to work must be obtained for all work within fifteen (15) meters distance from all

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    boundaries of existing facilities. These permits can be obtained from QP and twenty four (24)
    hours notice should be given to prevent delays.

    5
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    Mechanical or hydraulic rock breakers shall not be used adjacent to gas, oil or NGL pipelines.
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    6 Should jackhammers be required within two (2) meters of any buried pipelines and between
    any pipelines running in the same easement all round pipe protection must be provided
    as

    before commencement
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    7 Pilot holes to locate existing lines shall be dug by hand tools only, before allowing mechanical
    equipment to operate within five (5) meters of a QP live gas, oil or NGL pipelines.
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    8 Prior to exposure of any live pipeline the Contractor shall erect a suitable and substantial
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    barrier to prevent any damage to QP pipelines. This is particularly important where there are
    heavy vehicles in the vicinity and the possibility that removal of the bond for trenching
    operations opens up an illegal vehicle crossing.
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    9 When backfilling an exposed section of pipeline, naturally occurring soft dune sand shall be
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    used and the pipeline shall be covered and re-bedded all round with 150 mm minimum of
    sand. The remaining height of the bund will be made up of selected desert fill with particle
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    size not exceeding 150mm from organic material. QP engineer shall witness the backfill
    work, particularly the soft sand bedding operations.

    10 When trenching between pipelines in the same easement, vehicle access between the
    pipelines must be maintained.

    11 The maximum length of exposed unsupported pipeline must not exceed seven (7) meters.
    When it exceeds five (5) meters, a central substantial wooden support shall be installed
    within a minimum 10 mm thick rubber shoe contacting the pipe.

    12 When the bund is removed from any existing line its buried route shall be clearly indicated by
    pegs and warnings.

    13 Any damage to the pipe external protecting wrapping caused by the Contractor will be
    repaired in strict accordance with QP procedures at the Contractors cost.
    QCS 2014 Section 06: Road Works Page 13
    Part 14: Works in Relation to Services

    14 Provision of a permit-to-work by QP does not release the Contractor from obligation of


    obtaining relevant permits to expose or work near utilities/facilities not under QP area of
    responsibility. Examples QGEWC, Telecom Provider etc.

    14.3.5 PWA, Storm water and Groundwater

    1 This subclause of the specification covers; stormwater and groundwater drainage, foul water
    drainage and treated sewage effluent systems.

    2 All of the material submission, inspection & testing, preparation of record sheets, preparation
    of record drawings for works associated with PWA shall be carried out in accordance with the
    requirements of this part of the specification.

    3 Where it is necessary to make a connection to an existing water service this shall be in


    accordance with Part 14 of this Section.

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    4 Works shall be in accordance with the latest PWA standard details except as modified in this

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    Part. Contractors are deemed to be in possession of the latest standard details. Before
    beginning any work, the Contractor shall approach PWA and obtain a copy of their latest
    specification & standard details relating to the Works.

    5 ta
    All work shall be carried out by a contractor or subcontractor prequalified and approved by
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    PWA. Proof of such approval shall be required in writing before the start of Works on the
    Site and the name of any subcontractor to be used shall be as designated.
    as

    END OF PART
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    QCS 2014 Section 06: Roadworks Page 1
    Part 15: Road Lighting

    15 ROAD LIGHTING .................................................................................................... 4


    15.1 GENERAL ............................................................................................................... 4
    15.1.1 Scope of Works 4
    15.1.2 References 5
    15.1.3 Approved Contractors 6
    15.1.4 Supply of Materials 6
    15.1.5 Programme of Work 7
    15.1.6 Technical Requirements 7
    15.2 APPROVAL OF EQUIPMENT ................................................................................. 7
    15.2.1 General 7
    15.3 STORAGE OF PLANT AND EQUIPMENT .............................................................. 9
    15.4 SPECIAL REQUIREMENTS .................................................................................... 9

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    15.5 HIGH MAST LIGHTING ......................................................................................... 10

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    15.5.1 General 10

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    15.5.2 High Mast Column 10
    15.5.3 High Mast Head Frame 11
    15.5.4
    15.5.5
    High Mast Luminaire Ring
    Multi Core Mast Rising Cable ta 11
    12
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    15.5.6 Raising and Lowering Equipment 12
    15.5.7 Raising and Lowering Winch System 13
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    15.5.8 Finish 14
    15.5.9 High Mast Luminaires 14
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    15.5.10 High Mast Distribution Equipment 15


    15.5.11 Aircraft Obstruction Light 15
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    15.5.12 Earthing and Lightning Protection 16


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    15.5.13 High Mast Foundations Construction Requirements 16


    15.5.14 High Mast General Requirements 16
    15.5.15 High Mast Approval 17
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    15.5.16 Maintenance Requirements 17


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    15.5.17 High Mast Portable Cage for Maintenance 17


    15.5.18 High Mast Lighting Performance 18
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    15.6 LIGHTING COLUMNS ........................................................................................... 18


    15.6.1 General 18
    15.6.2 Design Criteria for Columns 18
    15.6.3 Details of Column 18
    15.6.4 Details of Bracket 19
    15.6.5 Doors and Base Compartments for Columns 20
    15.6.6 Details of Base Flange Plate 20
    15.6.7 Details of Column Foundation 21
    15.6.8 Passively Safe Lighting Columns 21
    15.6.9 Decorative Lighting Columns 23
    15.7 LIGHTING UNITS .................................................................................................. 24
    15.7.1 General 24
    15.8 CONTROL GEAR .................................................................................................. 25
    15.8.1 General 25
    QCS 2014 Section 06: Roadworks Page 2
    Part 15: Road Lighting

    15.9 LAMPS .................................................................................................................. 25


    15.9.1 General 25
    15.10 LIGHTING SYSTEM FOR UNDERPASSES .......................................................... 26
    15.10.1 General 26
    15.10.2 Vehicular Underpass 26
    15.10.3 Pedestrian Underpass 26
    15.10.4 Animal Underpass 26
    15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses 27
    15.10.6 Underbridge or Undercrossing Lantern and Installation 28
    15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps 29
    15.10.8 Underpass, Underbridge or Undercrossing Isolating Box 30
    15.11 LED LIGHTING UNITS .......................................................................................... 30
    15.11.1 Lighting Units 30

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    15.11.2 Lighting Performance 31
    15.11.3 Thermal Management 32

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    15.11.4 Testing 33
    15.11.5 In Situ Temperature Measurement Test (ISTMT) 34
    15.11.6
    15.11.7
    Control Gear
    LED Lamps ta 34
    36
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    15.11.8 Quality Criteria for LED Lighting 37
    15.11.9 LED manufacturers data 38
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    15.12 OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION ............................. 38


    15.12.1 General 38
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    15.12.2 Sign Gantry Lantern 39


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    15.12.3 Sign Gantry Lantern Control Gear and Lamps 40


    15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables 41
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    15.13 PHOTO ELECTRIC CONTROL CELL ................................................................... 41


    15.13.1 General 41
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    15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS ........................................... 42


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    15.14.1 General 42
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    15.15 FEEDER PILLAR ................................................................................................... 43


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    15.15.1 General 43
    15.15.2 Cabinet 43
    15.15.3 Components of Feeder Pillars 44
    15.16 ROAD LIGHTING CABLES ................................................................................... 45
    15.16.1 Underground Cables 45
    15.16.2 Packing of Cables 45
    15.16.3 Insulated PVC Sheathed Circular High Temperature (85C) 46
    15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES .................................. 46
    15.17.1 General 46
    15.17.2 Material & Quality 46
    15.18 MARKER POSTS .................................................................................................. 46
    15.18.1 General 46
    QCS 2014 Section 06: Roadworks Page 3
    Part 15: Road Lighting

    15.19 EARTHING ............................................................................................................ 46


    15.19.1 General 46
    15.20 INSTALLATION ..................................................................................................... 47
    15.20.1 General Requirements 47
    15.20.2 Temporary Lighting 48
    15.20.3 Removal of Existing Columns 48
    15.20.4 Detailed Drawing for RCC foundation 49
    15.20.5 Road lighting Column/Lantern Installation 49
    15.20.6 Road lighting Feeder Pillar Installation 50
    15.20.7 Road lighting Cable Installation 50
    15.20.8 Road Crossing Ducts 51
    15.20.9 Backfilling and Re-instatement 52
    15.20.10 Road lighting Cable Terminations and Testing 52

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    15.20.11 Electrical Power Supply 53

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    15.21 TESTING AND COMMISSIONING ON SITE ......................................................... 53

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    15.21.1 General 53
    15.21.2 Electrical Tests 53
    15.21.3 Photometric Performance Testing
    ta 54
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    15.22 RECORD DRAWINGS .......................................................................................... 55
    15.22.1 General 55
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    QCS 2014 Section 06: Roadworks Page 4
    Part 15: Road Lighting

    15 ROAD LIGHTING

    15.1 GENERAL

    15.1.1 Scope of Works

    1 Work related to the road lighting installation provided for in this specification shall include the
    supply, installation, testing, commissioning and putting into satisfactory operation any or all of
    the following systems as required by the project drawings.

    (a) Road lighting (L.V) cables and terminations.


    (b) Road lighting Feeder Pillar and internal associated control equipment including
    photocell control.

    .
    (c) Road lighting column/lantern assemblies.

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    (d) High mast lighting mast/lantern assemblies.

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    (e) Roadway Lighting System control, adaptive, smart or remotely managed
    (f) Lighting network earthing, including electrical grounding.
    (g)
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    Installation testing including lighting performance verification.
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    (h) Provision of equipment technical and maintenance data.

    2 The Contractor shall provide the shop drawings and supporting calculations required by the
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    specification, as well as the provision of all required supporting technical literature and
    samples in connection with the approval of proposed equipment.
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    3 The equipment supplied shall include all necessary items for a complete installation
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    according to the specification requirements in order to provide for satisfactory operation, not
    withstanding errors and omission. The equipment listed in the Contract documents are,
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    therefore, indicative and not limitative.


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    4 On satisfactory completion and commissioning of the lighting installation the Contractor shall
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    be responsible for the maintenance of the whole system for a period of 400 days. This will
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    include for the free replacement of any component or lamp that fails during that period of
    time. In addition, the Contractor shall be responsible for the rectification of any fault that
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    occurs within the cabling network. As part of this rectification work no cable joints will be
    permitted.

    5 All of the works associated with the road lighting installation shall be carried out in
    accordance with the "Regulations for the Lighting of Roads for Motorised Traffic" and the
    latest specifications issued by the PWA including The Qatar General Electricity & Water
    Corporation KAHRAMAA Regulations for the Installation of Electrical Wiring, Electrical
    Equipment.

    6 The Contractor is deemed to be in possession of these regulations and the latest


    specifications.

    7 The luminaire shall be suitable for connection to the low voltage single phase supply of the
    main network grid in The State of Qatar.
    QCS 2014 Section 06: Roadworks Page 5
    Part 15: Road Lighting

    15.1.2 References

    1 The following standards and other documents are referred to in this Part:
    ANSI/IESNA RP-008 ..Roadway Lighting
    BS HD 60269-2 ..........Low Voltage Fuses. Supplementary requirements for fuses by
    authorized persons (fuses mainly for for industrial application)
    BS 302........................Specification for higher breaking load ropes
    BS 791........................Solid-stem calorimeter thermometers
    BS 1011......................Process of arc welding of carbon and carbon manganese steels
    BS 2484......................Straight concrete clayware cable covers
    BS 4343......................Plugs, socket-outlets and couplers for industrial purposes
    BS 4360......................Weldable structural steels

    .
    BS 4533......................Luminaires

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    BS 4800...................Colour chart

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    BS 5467......................Cables with thermosetting insulation for electricity supply for rated
    voltages of up to and including 600/1000 V and up to and including
    1900/3300 V

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    BS 5486......................Low voltage switch gear and control gear assemblies
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    BS 5489......................Road lighting
    BS 5649......................Lighting columns
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    BS 5972......................Photoelectric Control Units for Road Lighting


    BS 6121......................Mechanical Cable Glands for Elastomer and Plastic Insulated Cables
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    BS 6141......................PVC insulated PVC sheathed circular flexible cables


    BS 6346......................PVC-insulated Cables for electricity Supply
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    BS 6360......................High conductivity stranded copper shaped conductor with XLPE


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    insulation
    BS 6622......................Cables with extruded cross-linked polyethylene or ethylene propylene
    rubber insulation for rated voltages from 3800 / 6600 V up to 19 000 /
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    33 000 V
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    BS 6746......................Extruded black PVC over sheath


    BS 6977......................Specification for insulated flexible cables for lifts and other flexible
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    connections
    BS 7430......................Code of practice for earthing
    BS 7671......................Requirements for electrical installations

    BS EN 40.................Lighting Columns
    BS EN 295..................Vitrified clay pipes, fittings and pipe joints for drains and sewers
    BS EN 1011................Welding
    BS EN ISO 1461 ........Hot dip galvanized coatings on iron and steel articles
    BS EN1559-1 ............Founding. Technical conditions of delivery. General.
    BS EN1559-4 ............Founding. Technical conditions of delivery. Additional requirements for
    aluminium alloy castings.
    BS EN1676.................Aluminium and aluminium alloys. Alloyed ingots for remelting
    BS EN 10137..............Plates and wide flats made of high yield strength structural steels
    QCS 2014 Section 06: Roadworks Page 6
    Part 15: Road Lighting

    BS EN 10210..............Hot-finished hollow sections


    BS EN 12767...........Passive Safety of Support Structures
    BS EN 60529..............Degrees of protection provided by enclosures
    BS EN 60898..............Miniature and moulded case circuit breakers
    BS EN 60947-3 ..........Air-break switches, air-break disconnectors, air-break switch
    disconnectors and fuse combination units for voltages up to and
    including 1000 V ac and 1200 V dc.
    BS EN 62305..............Protection against the lighting
    IEC 60598 ..................Luminaires for roadway lighting
    CIE 126-1997 ............Guidelines for minimizing sky glow.
    EN62262:2002 ..........(IEC62262:2002) Degrees of protection provided by enclosures for
    electrical equipment against external mechanical impacts.

    .
    The Qatar General Electricity & Water Corporation KAHRAMAA Regulations for the

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    Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment.

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    The Qatar Highway Design Manual (QHDM). Current edition.

    WEEE Directive (2002/96/EC).


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    RoHS Directive (2002/95/EC).

    Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety


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    Institution of Lighting Engineers (ILE), Technical Report No 7 High Masts for Lighting and
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    CCTV
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    ISO 9001, Quality Management Systems


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    Institution of Electrical Engineers (IEE), Wiring Regulations


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    State of Qatar, Qatar Wiring Regulations


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    American Association of State Highway and Transportation Officials (AASHTO) Roadside


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    Design Guide
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    15.1.3 Approved Contractors

    1 All road lighting works shall be carried out by a contractor or sub-contractor approved by the
    PWA. Proof of such approval shall be required in writing prior to the works commencing on
    site and the name of any sub-contractor to be engaged shall be entered in appropriate forms
    during tender submittal.

    15.1.4 Supply of Materials

    1 The Contractor shall supply all the materials required to carry out the Works as specified in
    the Contract Documents and Drawings. No materials will be supplied by the Owner or the
    PWA.
    QCS 2014 Section 06: Roadworks Page 7
    Part 15: Road Lighting

    15.1.5 Programme of Work

    1 The Contractor is responsible, with the agreement of the Engineer, for all liaisons with the
    respective department within PWA, in respect of programming the installation and
    commissioning of the complete road lighting system. In addition to the Engineer, he shall also
    ensure that relevant departments within the PWA are at all times kept informed of the current
    progress of the road lighting works on site and that his approved sub-contractor programme
    works are in the specified sequence in accordance with the overall approved Works
    programme.

    15.1.6 Technical Requirements

    1 All works carried out on the installation shall be in accordance with the requirements of these
    specifications so that their true meaning and intent are fulfilled. Minor deviations from the
    drawings may be made to accomplish this but no change shall be made without written

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    approval of the Engineer and in consultation with the relevant departments within the PWA.

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    2 In addition to all the regulations, codes of practice and standards referred to within this
    specification, all the lighting and associated electrical works shall comply with the current
    Qatar wiring regulations and the requirements of PWA.

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    3 Where applicable, any associated work involving other authorities in the State of Qatar their
    relevant standards and specifications, as issued by them, shall be complied with.
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    4 All equipment and materials supplied for the project shall be manufactured in strict
    compliance with the latest standard of BS, IEC, EN their equivalent AASHTO or other
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    standards and regulations specifically referred to in this specification. Here in after they are
    referred to as the Standards.
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    5 Acceptance tests shall conform to those referred to in the above mentioned Standards.
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    15.2 APPROVAL OF EQUIPMENT


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    15.2.1 General
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    1 All materials shall be approved by the Engineer. The Contractor shall be responsible to
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    ensure that, where applicable, for nominated items of equipment only the type and
    manufacturer approved by the PWA, as detailed in their List of Approved Manufacturers are
    submitted for incorporation into the works. In addition, written approval must be obtained
    from the PWA, prior to ordering. Contractors shall note that only products with a proven
    record of performance, efficiency and long life will be considered for approval.

    2 The Contractor shall not order any equipment for the incorporation into the Works before
    receipt of formal approval in writing. The approval procedure shall be as follows:

    (a) The Contractor shall submit four copies of his equipment proposals to the Engineer.
    This submission shall be comprehensive and clearly state any manufacturers
    deviations from the specification. Manufacturers literature associated with the
    submission shall be originals and not photocopies. Specific reference to the
    compliance of certain specification requirements shall be identified.
    (b) The Engineer shall review this submission. The Engineers approval shall be as
    follows.
    QCS 2014 Section 06: Roadworks Page 8
    Part 15: Road Lighting

    (i) With the Engineers comments and recommendations attached, a copy of the
    submission shall be forwarded to the departments concerned within the PWA, to
    obtain their approval.
    (ii) Where minor deviations exist from the specifications but do not affect the
    performance of the equipment or installation the Engineers recommendations to
    accept such deviations, his approval together with a copy of the submission
    shall be forwarded to the departments concerned within the PWA, to obtain their
    approval.
    (iii) Approval shall be transmitted to the Contractor in writing once the approval of
    the relevant departments within the PWA, has been given.

    3 All submissions shall give clear, unambiguous details and performance data of the
    equipment proposed, together with all supporting calculations where necessary. Clear
    catalogue identification references shall be provided. Documents shall be in English.

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    4 The Engineer reserves the right to direct the Contractor to provide equipment of a make and

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    type that is essential to achieve the Contract design criteria.

    5 Approval of samples by the Engineer in consultation with the relevant departments within the

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    PWA, does not in any way relieve the Contractor of his contractual obligation in respect of the
    suitability of the equipment or their final performance once installed, and the co-ordination
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    with all the elements of the lighting works into a fully operational installation.
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    6 After receipt of equipment the Contractor shall arrange for them to be examined and
    approved by the Engineers Representative in consultation with the relevant department
    within the PWA, prior to installation.
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    7 Column and Mast Fabrication Requirements


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    In paved or walkways areas Enclosure plate is required. The Enclosure plate shall be cast
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    Aluminium or Galvanized steel, comprising two removal halves per base with size matching
    the base plate. It shall be painted to match pole finish. Provided with backup plate to one
    halve of Enclosure Plate and with tapped holes to accept stainless steel screws countersunk
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    into other half of Enclosure Plate.


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    8 Specific Requirements for Columns


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    The gap between base plate and top of foundation shall be grouted. Means of discharging
    any accumulated moisture shall be provided at the pole base and provision shall be made for
    adequate drainage.

    9 Testing and Factory Visits

    The contractor shall facilitate authorised Engineer representatives, and/or their appointed
    representative, to examine the test and manufacturing facilities and witness
    manufacturing processes and sample testing related to the luminaire and associated
    components submitted for evaluation, at no cost to Ashghal or their appointed
    representative.
    QCS 2014 Section 06: Roadworks Page 9
    Part 15: Road Lighting

    10 Saving Energy Lamps Luminaire specification data sheet arrangement or each model of
    luminaire the manufacturer shall produce a data sheet providing a detailed and
    comprehensive description of the luminaires characteristics and component parts. The data
    sheet will contain adequate information for the reader to select and specify a particular model
    from the luminaire range. This will include;

    (a) luminaire diagram external dimensions, weight and windage


    (b) optical arrangement (lens and reflectors types and settings)
    (c) driver type (drive current, system power consumption)
    (d) luminaire output (lm)
    (e) luminaire efficiency (lm/W)

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    (f) glare rating

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    (g) control and switching options (photocell, programmed stand alone, CMS, etc.)

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    15.3 STORAGE OF PLANT AND EQUIPMENT

    1
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    All plant and equipment shall be stored off the ground under weatherproof cover ready for
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    incorporation in the works. All electrical apparatus shall be examined and cleaned before
    installation. All open conduit ends shall be fitted with plastic caps or suitable protective
    covering to prevent the ingress of foreign matter. All drums with cables shall be protected
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    from direct sunlight.


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    15.4 SPECIAL REQUIREMENTS


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    1 All notices from the Contractor shall be in writing and delivered by hand.
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    2 The Contractor shall consult the Engineer not less than one month before it is proposed to
    commence work to ascertain whether any underground installations will be affected by the
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    proposed work, in which event the Contractor shall make all necessary arrangements with
    the Engineer to safeguard the installation. It will be the Contractors responsibility to liaise with
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    the utility authorities and to arrange for all road opening notices
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    3 The Contractor shall give at least one week's notice in writing to the utility authoritys
    Engineer of the dates upon which it is intended to operate plant or equipment or carry out any
    work for which permission has been given in writing by the utility authoritys Engineer. Such
    operations of work shall only be carried out in the presence of the utility authoritys Engineer
    unless notice shall have been in writing from the utility authoritys Engineer that they do not
    require to be present.

    4 The utility authorities may require work to be executed on their installation during the period
    of the Contract. The Contractor shall afford all facilities to the utility authoritys contractors or
    workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
    the utility authorities and his own activities and when necessary shall amend his programme
    of working to suit all requirements of the utility authorities in connection with their diversion
    work and shall keep the Engineer informed in writing of all arrangements made.
    QCS 2014 Section 06: Roadworks Page 10
    Part 15: Road Lighting

    5 The Contractor shall locate and mark with suitable posts all the utility authoritys underground
    installations that are within the area of the Works and shall ensure that such markers are
    maintained in their correct positions at all times. The Contractor shall advise the utility
    authoritys agent of any installation not found where shown on the Drawings, or found but not
    shown or found damaged or subsequently damaged.

    15.5 HIGH MAST LIGHTING

    15.5.1 General

    1 This work shall consist of the supply, installation upon prepared foundations, connections,
    commissioning and putting into satisfactory service the high masts complete with the
    operating mechanisms, luminaire support ring or bracket, luminaries, control gear, wiring and
    distribution equipment.

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    2 The mast luminaire support ring shall be designed to provide for the appropriate distribution
    of lighting either in one direction or in many directions thus making it possible to concentrate

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    the required number of luminaires on any zone and fix them rigidly in any direction desired.
    Prepared foundations are specified in other sections of this specification.

    15.5.2 High Mast Column


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    qa
    1 The high mast column shall be of the height specified on the Drawings, hot dipped
    galvanized to BS EN ISO 1461 or BS 791 of multi-sided cross-section with a continuous
    as

    taper made of formed sheet steel in accordance with BS 4360 grade 43C and electrically
    welded. They shall be delivered to the site in manageable sections of not greater than 12
    se

    metres and be joined by means of pressure over-lapping or slip-joints, which shall have a
    minimum length of 1.5 times diameter of the joint. Site welding will not be allowed.
    er

    2 The walls of the masts shall have a minimum thickness of 6mm for the base section, 5mm
    ov

    for the central section and 4mm for the top section. The steel used shall have tensile strength
    between 490 and 630 MN/sqm and minimum yield strength of 355 MN/sqm.
    o

    3 The mast cross-sections shall be so designed that once installed and fully equipped, it shall
    it

    have safety factors in accordance with Technical Report No. 7 of the Institute of Lighting
    et

    Engineers London and shall be capable of withstanding wind load resulted from the wind
    m

    speed provided in Section 1 Part 1 Clause 1.5.2, and blowing in the most unfavourable
    direction at a height of ten meters above ground level. Appropriate reinforcement shall be
    provided where necessary to increase the strength. Its behaviour under wind induced
    oscillation shall be such that it shall not fail due to fatigue and the design should ensure that
    these oscillations be damped to a minimum of zero.

    4 The maximum deflection at the top of the mast shall not exceed 2.5% of the mast height at
    the minimum wind speed provided in Section 1 Part 1 Clause 1.5.2.

    5 A steel flange plate of adequate thickness and free from laminations shall be welded above
    and below the base of the mast developing fully the strength of the section. In addition
    supplementary gussets shall be provided between bolt holes if deemed necessary.
    QCS 2014 Section 06: Roadworks Page 11
    Part 15: Road Lighting

    6 An access door shall be provided in the base of the mast of adequate dimensions to permit
    clear access to the back plate installed for the mounting of the circuit breaker assembly and
    junction box, winch, etc. The backboard shall be made of steel or other non-hydroscopic
    material. The door shall be completely weatherproof fitted with a hidden hinge and a heavy
    duty lock. The door area shall have appropriate reinforcement.

    7 A stainless steel earthing 12mm diameter bolt shall be welded inside the mast near the
    access door and shall be complete with stainless steel washers and nuts.

    15.5.3 High Mast Head Frame

    1 The head frame shall be hot-dipped galvanized steel attached to the mast by means of a
    steel slip-fitter and secured by at least four stainless steel set screws. It shall be composed of
    spun aluminium or other approved weatherproof cover, housing the required number of steel
    cable sheaves and associated accessories for the operation and powering of the luminaire

    l .
    ring.

    .l.
    rw
    15.5.4 High Mast Luminaire Ring

    1 The high mast luminaire support ring or carriage shall be constructed of hot dipped

    ta
    galvanized steel channel fitted with the appropriate number of luminaires, lamp gear
    qa
    mounting brackets, wiring chamber and mounting plate. It shall be in two halves joined by
    bolted flanges to permit removal from the erected mast. The luminaire shall be mounted on
    the luminaire rings by means of either a specially designed bracket allowing it to be swiveled
    as

    in any desired direction or rigid bracket arm assembly. It shall be possible to lock each
    luminaire firmly in position, thus preventing any rotation or falling while moving the luminaire
    se

    ring.
    er

    2 The carriage assembly shall be arranged to locate firmly against stops when in the secure
    position and these shall be of adequate strength to ensure that they cannot be damaged by
    ov

    over winding of the winch.

    3 A shaped protective aesthetic canopy, designed to give a coordinated appearance of head


    o

    frame with the luminaire ring, shall cover the head frame.
    it
    et

    4 For masts fitted with a mobile luminaire ring, rollers with a centering mechanism shall be
    provided to ensure a perfect alignment of the luminaire ring both axially and in azimuth, while
    m

    ascending or descending the mast. Rollers shall be made of water resistant non-marking
    composition material with oil-impregnated bronze brushings. All shafts and washers shall be
    stainless steel.

    5 A weatherproof wiring chamber or terminal box shall be provided constructed from a


    corrosion resistant material or aluminium alloy and installed on the luminaire ring. It shall be
    equipped with the high temperature shrouded terminal blocks and neutral bar or block and
    shall include facilities on the luminaire ring to allow testing of luminaires while in the lowered
    position. The wiring chamber shall be fitted with an earthing stud accessible from inside and
    out for earthing connections. The housing shall be completely weatherproof.

    6 The cables installed in the luminaire ring connecting each luminaire to the wiring chamber
    shall be factory pre-wired avoiding the need for field wiring, and shall have single core copper
    conductors with neoprene or cross-linked polythene or approved equivalent insulation and
    2
    sheath. Cables shall be either single core or 3 core 2.5mm with copper conductors and
    colour coding of the different phases being in conformity with the relevant cabling standards.
    QCS 2014 Section 06: Roadworks Page 12
    Part 15: Road Lighting

    7 Cables from the terminal box shall run in PVC duct or metal duct fixed to or within the
    luminaire carriage to each luminaire from the wiring chamber.

    15.5.5 Multi Core Mast Rising Cable

    1 The cable connecting the MCCB assembly at the base of the mast to the wiring chamber on
    the luminaire ring, shall be a flexible multicore copper cable with conductors and neoprene or
    approved equivalent high temperature resistant insulation and sheath in accordance with BS
    6977.

    2 The colour coding of the different phases of the cable shall conform to the relevant cable
    standards. Each luminaire shall have its own neutral conductor connected to the neutral bar
    or block.

    3 The mast cable shall consist of a circular multi core cable to BS 6977 600/1000V grade.

    l .
    Each conductor core shall be insulated with ethylene propylene rubber (EPR) and the

    .l.
    complete core is sheathed with heavy duty polychloroprene (PCP).

    rw
    4 A multicore electrical power cable shall be provided terminating in the base compartment with
    a special multi-pin plug and socket coupler fitted with a guard, and at mast head connected

    ta
    to the wiring chamber fixed to the luminaire ring. It shall be suitable for the bending, flexible
    and load carrying stresses involved.
    qa
    5 The cable shall be fitted with a correctly rated multi pin weatherproof plug and socket within
    as

    the base compartment of the mast which will enable the cable to be disconnected before
    lowering the luminaire carriage. The socket must be connected to the supply side of the
    se

    circuit and may either be free cable coming from the fuse box or be fixed to the fuse box in
    the base compartment.
    er

    6 The wiring shall be such that the plug and socket can be isolated before disconnecting.
    ov

    7 The cable shall be suitably restrained to prevent its own weight from causing the terminal box
    to energise the lanterns.
    it o

    15.5.6 Raising and Lowering Equipment


    et

    1 The pulleys located within the headframe shall be of non- corrosive cast aluminium alloy
    m

    material grooved to exactly suit the steel rope and cable diameters, and fitted with stainless
    steel shafts. The pulleys shall be housed in a chassis integral with a sleeve, which slopes
    over the top of the mast and is secured axially and in azimuth. The complete chassis
    assembly shall be hot dipped galvanized. A guard is to be provided for the separation of the
    wire rope and power cable before entering in the pulley and the locating of the steel wire rope
    and power cables in their groves when operating either loaded or slack. An arrangement
    shall be provided to ensure that the electric and steel cables are separated before passing
    over their respective pulleys, and close fitting guides shall ensure that the cables cannot
    disengage the pulley during operations.

    2 The luminaire carriage shall have the provision made on it for supporting and gripping the
    weight of the supply cable without damage of the cable sheath.

    3 The luminaire ring shall be supported by 3 steel ropes coupled to 2 steel ropes and
    suspended from the double drum winch by means of a manufactured steel coupling unit. A
    divider bar shall ensure the separation of the steel ropes during raising and lowering.
    m
    et
    ito
    ov
    er
    se
    as
    qa
    ta
    rw
    .l.
    l .
    QCS 2014 Section 06: Roadworks Page 14
    Part 15: Road Lighting

    8 An MCCB providing overload protection shall be incorporated to stop the ring when the effort
    required by the winch becomes superior to the nominal load.

    9 The winch shall be fitted with suitable equipment to allow the winch to stop in a safe manner,
    without damage to the mast finish, in the event of a supply failure to the power tool. The
    winding mechanism should then be capable of being operated by hand.

    10 Each winch supplied shall be uniquely identified. In addition it shall have its own individual
    test certificate recording the safe working load. Lubrication details shall also be permanently
    recorded on its housing for future maintenance purposes.

    15.5.8 Finish

    1 All welds shall be smooth with the splatter removed and the interior and exterior surface of
    the mast and ring shall be cleaned by pickling or blasting and shall be free of any grease.

    l .
    .l.
    2 All components shall be hot dipped galvanized by total immersion in a bath of molten zinc

    rw
    after completion of the fabrication. No further levelling up, finishing or modifications shall be
    carried out after completion of the galvanizing process. The minimum thickness of zinc
    coating shall be 450 gm/sqm on the inside and outside surfaces of the mast and ring. The
    galvanizing shall conform to BS EN ISO 1461.
    ta
    qa
    3 Any damage to the galvanizing shall be rectified during erection by wire brushing the affected
    area and treating with an approved zinc restorative. Sufficient materials shall be applied to
    as

    provide a zinc coating at least equal in thickness to the galvanized layer.


    se

    4 If required by the Engineer the underside of the flange plate and internal surface of the mast
    to a height of 0.5m shall be given a coat of heavy duty bitumen paint prior to erection.
    er

    15.5.9 High Mast Luminaires


    ov

    1 The high mast luminaire shall have a cut off distribution. It shall be of the side entry
    mounting type, with toughen a flat glass protector and integral control gear suitable for the
    o

    operation of either a 400W with lumens per watt rating of no less than 48,000, or 600W with
    it

    lumens per watt rating of no less than 88,000, 220-240V, 50Hz. High Pressure Sodium
    et

    tubular lamp of E-40 base, as defined for the contract.


    m

    2 The luminaires to be adopted shall be high performance street lighting lanterns currently
    used for conventional roadway lighting routes to BS 5489 or equivalent suitable for use at a
    mounting height of 25 or 30 metre. It shall comply with IEC 60598 or other approved
    equivalent norms. The body shall be made of die-cast aluminium and shall be divided into
    two separate compartments.

    3 The first compartment of the luminaire shall house the optical system with polished and
    anodized pressure aluminium reflector. The second compartment shall contain the electrical
    accessories (control gear) cable feed terminals and side entry mounting socket. This
    separation shall protect the electrical accessories from the direct radiant heat emitted by the
    lamp. The optical compartment shall be protected by a toughened flat glass protector and
    shall be dust and watertight to a protection rating of IP65.
    QCS 2014 Section 06: Roadworks Page 15
    Part 15: Road Lighting

    4 The access to the optical compartment shall be by tilting the protector frame around the
    hinge without tools. A heat resistant gasket fitted on the frame shall ensure the tightness of
    the optical compartment. The accessories such as ballast, ignitor, and capacitor shall be re-
    wired and pre-assembled by a metallic plate that is mounted and fixed into the rear
    compartment. Special care shall be taken to allow easy maintenance and quick replacement
    of the accessories and to minimise the risk of falling.

    5 The cable feed terminal and the earth-screw shall be fixed to the metallic compartment, a
    cable holder shall be mounted near the terminals. The side entry mounting sockets should
    accept a 125 mm. long spigot and 50 mm diameter OR adjustable from 42 to 60 mm dia.
    Exterior side of both compartments should be with grey colour in finish.

    15.5.10 High Mast Distribution Equipment

    1 The high mast base compartment shall be fitted with a power control and distribution

    l .
    assembly installed in a pre-wired weatherproof box opposite the access door inside the base

    .l.
    of the mast.

    rw
    2 The assembly shall consist of a surface mounted sheet steel weatherproof box with a cover
    enclosing:

    (a) ta
    One 3-pole main 60Amp MCCB together with a neutral link for luminaire circuits. The
    qa
    ratings of the MCCB shall be in accordance with the QGEWC regulations and suitable
    to the connected load and cable.
    as

    (b) One single pole 20 Amp MCB with neutral link for each luminaire circuit of a suitable
    current rating.
    se

    (c) One-pole MCCB with neutral link connected to the incoming supply and serving a 16A-
    250 V DIN socket outlet complete with 3-pin plug to suit the raising and lowering
    er

    mechanism.
    ov

    (d) A multi-pin plug and socket outlet with guard fitted with cable outlet for connection to
    the multi-core electric power cable provided from the MCCB to the luminaire ring wiring
    chamber.
    it o

    3 The MCCBs shall be de-rated and calibrated to provide over-current and short circuit
    et

    protection when used in an ambient temperature of 50oC and shall have the required
    breaking capacity. The incoming side of the triple pole MCCB with the neutral links shall be
    m

    fitted with a 4-way, line-tap type terminal block, with each terminal capable of accepting 2 x
    2
    35mm copper conductors.

    4 The multi-pin coupler for supply to the portable raising and lowering power tool shall be
    connected to the MCCB via a flexible connection to ensure accessibility.

    5 Where an high mast assembly supplies a ground sign lighting unit or equivalent it shall be
    equipped with an additional 15 Amps circuit breaker to supply the sign lighting installation.
    The circuit breaker shall be installed inside the mast distribution box.

    15.5.11 Aircraft Obstruction Light

    1 Where required by Civil Aviation Authorities, two red luminaires within cast aluminium bodies
    shall be fitted at the top of each high mast attached to the movable luminaire ring with a
    purpose made bracket and arranged to project through the canopy.
    QCS 2014 Section 06: Roadworks Page 16
    Part 15: Road Lighting

    2 The luminaires shall be provided with a change over relay such that, in the event of lamp
    failure, the second lamp is automatically connected. Lamps shall be GLS Rough Service 100
    watt suitable for an E.S. (E27) lampholder.

    3 The obstruction lights shall be wired on a separate circuit protected by a separate SP & N
    circuit breaker with terminals to accept separate incoming cables.

    15.5.12 Earthing and Lightning Protection

    1 All masts shall be provided with a separate system for earthing as a protection against
    lightning. This shall comply with BS EN 62305.

    2 High masts shall be equipped with an air terminal of the correct height to provide the required
    zone of protection for the mast head frames and fixtures. The air terminal shall be bonded to
    the mast to ensure the discharge is dissipated via the earth ground terminal without damage

    l .
    to the steel winch ropes or electrical cables.

    .l.
    rw
    3 Separate earthing shall be provided for each item of control equipment within the mast
    assembly and connected to a central earthing point.

    4
    ta
    A 12mm diameter stainless steel or brass stud with nuts and washers in the base
    compartment connected to the main body of the mast structure shall be provided.
    qa
    15.5.13 High Mast Foundations Construction Requirements
    as

    1 High masts shall be installed on concrete bases as detailed on the Drawings. The foundation
    se

    design and construction shall be as based on the high mast manufacturers recommendations
    according to the ground and climatic conditions that exist at the site location. The erection of
    high masts and the assembly of the luminaire, head frame with raising and lowering gear
    er

    shall be carried out strictly in accordance with the manufacturers instructions. The Contractor
    ov

    shall before commencement of the construction work confirm by means of structural


    calculations that the foundations proposed are suitable for use with the high mast installation
    he proposes to install. Holding down bolts and plumb adjustment nuts, washers, locknuts or
    o

    nyloc nuts shall be galvanized steel or cadmium plated.


    it
    et

    2 The holding down bolt/nuts complete with the anchor plate for casting into the foundation
    shall be provided by the high mast manufacturer together with a mild steel anchor bolt
    m

    template with tube holes to ensure correct vertical and precision made horizontal bolt
    alignment.

    3 The anchor bolts shall be of guaranteed performance high tensile steel.

    4 All buried external surface of the high mast foundation shall be protected by brush painted
    tanking membrane and hard board protection.

    15.5.14 High Mast General Requirements

    1 Final setting and adjustment of the luminaires shall only be carried out after all the masts
    along a route, junction or interchange are complete and operational.

    2 Each high mast metal work shall be bonded to a separate earth rod as indicated on the
    Drawings and also to the separate earthing cable connected to the distribution system earth
    bar.
    QCS 2014 Section 06: Roadworks Page 17
    Part 15: Road Lighting

    3 The high mast shall be of specified height carrying luminaires as indicated on the Drawings.
    Each luminaire shall be fitted with the specific lamp or lamps arranged to be separately
    oriented to give the correct illumination at designated locations along the road surfaces.

    15.5.15 High Mast Approval

    1 For the approval of the Engineer before manufacturing commences the Contractor shall
    submit detailed calculations and supporting data to show that the mast meets the design
    criteria detailed and shall include the following information:

    (a) The deflection at the top of the mast at the designed wind speed.
    (b) The neutral frequency of the mast.
    (c) The critical wind speed for resonance.
    (d) The damping characteristics of the mast.

    l .
    .l.
    (e) The steel stressed under resonant conditions.

    rw
    (f) The acceleration at the top of the mast under resonant conditions.
    (g) Welding procedure.
    (h)
    ta
    Procedure to ensuring that the flange plate is not laminated.
    qa
    (i) Details of the joints between the mast sections and between the bottom section and
    the flange.
    as

    (j) Details of the base compartment with the method of reinforcement at the door area
    and means adopted for making the door weather and tamperproof.
    se

    15.5.16 Maintenance Requirements


    er

    1 The following items must be provided for the Engineer at the time of the commissioning of
    ov

    any high mast assembly:

    (a) Power tools 1 No.


    o

    (b) L hooks 6 No.


    it

    Operating handles 2 No.


    et

    (c)
    (d) Foundation Bolt/Nut and Head frame Nut/Bolt Spanners 2 No. Sets.
    m

    15.5.17 High Mast Portable Cage for Maintenance

    1 The high mast system shall incorporate a mobile luminaire ring such that it is suitable for
    utilising a purpose made portable cage for maintenance purposes.

    2 The cage shall be obtained from the high mast supplier and shall be capable of carrying two
    persons plus servicing equipment.

    3 A safety system shall be provided for use with the cage according to the manufacturers
    recommendations. One safety cage per project shall be allowed within the pricing structure
    offered by the Contractor for the future use of the Engineer.
    QCS 2014 Section 06: Roadworks Page 18
    Part 15: Road Lighting

    15.5.18 High Mast Lighting Performance

    1 The Contractor must provide guaranteed lighting performance data as part of his technical
    submission to confirm the minimum light values that will be maintained at each location and
    where specifically identified by the Engineer or representatives from the relevant departments
    within the PWA.

    2 The minimum light levels that must be obtained shall be:


    Horizontal illumination 30 LUX
    Diversity Factor (Ave/Min) 4:1

    15.6 LIGHTING COLUMNS

    15.6.1 General

    l .
    .l.
    1 All columns and brackets shall be produced by ISO 9001 certificated lighting column
    manufacturers registered and certified for the manufacture, supply and certification of lighting

    rw
    columns under their quality assessment schedule.

    2
    ta
    All columns of the same mounting height and with the same arrangement shall be identical in
    construction.
    qa
    3 Road lighting columns shall be hot dip galvanized steel, octagonal, multisided, tubular and
    stepped shape, of height as detailed in the Contract specification and drawings, complete
    as

    with bracket of outreach, number of arms and of shape all again as detailed in the Contract
    specification or on the drawings.
    se

    15.6.2 Design Criteria for Columns


    er

    1 For all columns and masts the stress and deflection calculations shall be based on the
    ov

    maximum bracket and luminaire projection, on the bracket arm, with projected area, length
    and weight as designated.
    o

    2 In still air conditions, loaded with the designated luminaire positioned in any of the variable
    it

    locations, there shall be no appreciable deflection of the column.


    et
    m

    3 The maximum permissible deflection in the column or mast shall be 1 in any 1m length with

    4 Columns must be designed to withstand the wind force.

    5 The "K" factor for columns over 8 m in height shall be 2.2.

    6 Columns shall be designed to support lanterns with the data given by the Engineer.

    15.6.3 Details of Column

    1 The column shall be made from hollow sections to BS EN 10210 in steel to BS 7613 grade
    43C or any approved equivalent norms. The hollow sections shall have a minimum tensile
    strength of 430 N/mm and minimum yield strength of 255N/mm.

    2 Columns shall be in one piece tubular (round), stepped shape or multi-sided sheet steel and
    be of the flanged (bolted) type.
    QCS 2014 Section 06: Roadworks Page 19
    Part 15: Road Lighting

    3 Columns should be designed in accordance with BS 5649 in steel and finished with hot dip
    galvanized internally and externally with no other treatment in accordance with BS EN ISO
    1461 or equivalent.

    4 The jointing of the column shall be carried out by reducing the diameter of the base section to
    form an interface fit with the bore of the upper section. The upper section shall be heated and
    pushed over the lower section. The thermal shrinkage shall ensure a complete bond over the
    full area of the joint and develop the full strength of column at the transition. The final
    operation is to weld the lower section to the upper section and dress the weld to a smooth
    profile. Welding shall be carried out in accordance with BS 1011.

    5 Strengthening shall be provided at the door opening. Care shall be taken to ensure that
    rounded edges are provided at the corners of the door opening to avoid stress
    concentrations.

    l .
    6 The top of the column should be designed and provided as suitable to fix the bracket arm

    .l.
    collar with the top of the column as shown in the Contract drawings.

    rw
    7 All dimensions for the column shall be in accordance with the latest requirements of the
    PWA, and, if applicable, as detailed on the drawings. Modifications to suit the particular

    ta
    foundation/support details proposed by the manufacturer shall be submitted to the Engineer
    qa
    for approval prior to incorporation.

    15.6.4 Details of Bracket


    as

    1 Brackets shall be formed of hollow sections to BS EN 10210 in steel to BS EN 10137 Grade


    se

    43C or equivalent.
    er

    2 The column bracket arms and spigots shall be so designed that when assembled with the
    shaft the design altitude of the arm and projection shall be as detailed in the contract
    ov

    requirements.

    3 Welding on bracket arm shall be carried out in accordance with BS EN 1011.


    it o

    4 Brackets shall be hot dip galvanized to BS EN ISO 1461 or equivalent. The bracket arm shall
    et

    be so designed that when assembled on the column shaft the altitude of the arm and spigot
    shall be 5 above the horizontal unless otherwise stated in the Contract documents.
    m

    5 Length of the luminaire fixing spigot unless otherwise designated to suit the luminaire shall be
    150mm, outside diameter of spigot shall be 42mm, thickness shall, be 4mm.

    6 The securing arrangement of the bracket arm to the column shall be positive so as to ensure
    that the arm does not rotate and shall be such that the bracket can be fixed in any of four 90
    degree positions in relation to the column door opening. 8 No. socket set screws of size M10
    x 16mm or approved equivalent arrangement shall fix the bracket onto the columns using
    stainless steel screws.

    7 The luminaire shall be securely fixed to the mounting post or bracket by means of a
    clamping system that will prevent movement in high winds. All component parts shall be
    manufactured from non-corrosive materials.
    QCS 2014 Section 06: Roadworks Page 20
    Part 15: Road Lighting

    15.6.5 Doors and Base Compartments for Columns

    1 Each column and mast shaft shall have a base compartment large enough to offer easy
    access to the equipment therein.

    2 The weatherproof door provided for each opening which shall be interchangeable between
    columns of the same mounting height. To avoid accidental spillage of water from irrigation of
    flooding the bottom of the door shall be at least 0.5m above the top of the foundation.

    3 A stainless steel durable non-corroding tamper-proof lock device shall be provided of the
    triangular headed screw type, unless designated otherwise. Where applicable, door lock
    recess shall incorporate adequate drainage such that they are unlikely to become blocked
    and so form a water trap.

    4 Door openings are to be kept to the minimum size consistent with the cable termination units

    l .
    and any control gear.

    .l.
    rw
    5 When installing lighting columns on a single carriageway the column doors shall be located at
    90 to the kerb line and in such a location that the maintenance operative faces the oncoming
    traffic and to ensure that the door can be opened at all times without encroaching onto the

    ta
    highway. In the case of installing lighting columns within the central median the column door
    shall be located perpendicular to the road such that the maintenance operative will be facing
    qa
    across the line of the carriageway. The door openings shall be free from any irregularities
    and burrs.
    as

    6 Keys are to be provided with the first consignment of columns at the rate of 10 % of the total
    se

    number of columns.
    er

    7 A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely


    fixed in each compartment and shall be of sufficient size to accommodate the cable
    ov

    termination unit.

    8 Single purpose earth terminals shall be provided in a readily accessible position, preferably
    o

    on the left hand side of the opening and on the column door.
    it
    et

    9 The baseboard shall be fixed using brass or stainless steel nut and bolt arrangement.
    m

    10 All door lock hinges and catches shall be greased before handover.

    15.6.6 Details of Base Flange Plate

    1 The base flange plate shall be manufactured from steel plate that is free from laminations.
    The main shaft of the pole shall penetrate the full depth of the base plate and is to be welded
    above and below using a semi automatic MIG shielded arc process. Additional strength shall
    be provided by gusset plates located between hole positions.

    2 4 No. slots allowing for adjustment shall be provided in the flange plate of suitable size so as
    to accommodate the foundation bolt specified to fix the column on the RCC foundation.
    QCS 2014 Section 06: Roadworks Page 21
    Part 15: Road Lighting

    15.6.7 Details of Column Foundation

    1 The manufacturer of the road lighting column shall submit the dimensions and specification
    of his proposed foundation including the steel reinforcement details to the Engineer for
    approval.

    2 The foundation shall accommodate 4 No. holding down bolts of size 25mm x 800mm for
    columns up to 10 metres high and 33mm x 900mm for 12 and 16 metres high columns,
    supplied with two nuts and two washers to each bolt.

    3 Foundations shall be constructed such that they avoid being a hazard to pedestrians
    and bicyclists on footways and shared use paths. The top surface of concrete column
    foundations on pathways shall not be higher than ground level, and shall not be higher than
    50 mm above ground level on all other surfaces.

    l .
    15.6.8 Passively Safe Lighting Columns

    .l.
    rw
    1 Design Criteria

    (a) All Passively Safe lighting Columns shall comply with BS EN 12767 Passive safety of

    ta
    support structures for road equipment requirements, classification and test methods,
    2007 or all road lighting columns within the clear zone (as AASHTO Roadside Design
    qa
    Guide Table 3.1 or Chapter 10 Roadside Safety Urban or Restricted Environments)
    shall be protected by an approved barrier system.
    as

    (b) Each Passively Safe Lighting Column shall be anodized aluminium or galvanized steel
    as specified in the Contract Documents. Design of aluminium columns shall
    se

    comply with BS EN 40, Part 6 and its incorporated references. Design of steel
    columns shall comply with BS EN 40, Part 5 and its incorporated references.
    er

    (c) In addition to section 15.6.2-1 the passively safe columns in still air conditions, loaded
    ov

    with the designated luminaire positioned in any of the variable locations, there shall be
    no appreciable deflection of the column. The maximum permissible deflection for
    passively safe poles shall not exceed 4% of the total length of the pole when furnished
    o

    with bracket arm, and 2% of the total length of pole with no bracket arm. Columns
    it

    must be designed to withstand a base wind speed of 30 metres/second. Columns


    et

    shall be designed to support lanterns with the data given by the Engineer.
    m

    (d) Per BS EN 12767, Annex F, passively safe tubular hollow section steel or
    aluminium posts provided shall have a nominal diameter less than or equal to 89
    mm, and a nominal wall thickness of 3.2 mm. Where steel poles are specified in the
    Contract Documents, steel grade S355J2H shall be provided.
    (e) Aluminium columns shall be finish coated with an anodized aluminium finish
    providing resistance to fading, peeling, cracking or corrosion. The guarantee provided
    by the manufacturer shall be a minimum of 10 years against fading, peeling, cracking
    or corrosion of the finish.
    (f) The maximum mass of combined luminaire support and fixtures attached to
    breakaway supports shall be limited to 450 kg and the maximum column height shall
    not exceed 18.0 metres.
    (g) Where slopes are greater than 6:1, no passively safe support shall be used without the
    approval of the Engineer. Passively safe supports shall not be used on any
    columns mounted on median barriers, concrete or otherwise. No slip base
    mechanisms may be used on Qatar roadways.
    QCS 2014 Section 06: Roadworks Page 22
    Part 15: Road Lighting

    (h) Columns shall be certified by the manufacturer to comply with BS EN 12767 and shall
    achieve the Passive Safety Performance Classes as indicated in Table 15.1.
    Table 15.1 Passive Safety Performance Classes
    Pole Support Requirement
    Roadway Posted Impact Speed Class*/ Energy
    Location
    Speed Absorbing Type / Occupant
    Safety Level**
    (a) 70:HE:1-3
    (b) 100:HE:1-3
    40 kph All
    (c) 70:LE:1-3
    (d) 100:LE:1-3
    CBD 100:HE:1-3

    .
    Other 100:NE:1-3

    l
    .l.
    40 kph Where columns may fall
    100:HE:1-3

    rw
    on other carriageways
    below (i.e. flyovers).
    HE High Energy Absorbing
    Term Descriptions ta
    CBD Central Business District LE Low Energy Absorbing
    qa
    NE Non-Energy Absorbing
    * Poles shall be procured in order of class per availability from the manufacturer.
    ** The Occupant Safety Level (OSL) provides for increasing levels of safety by reducing impact
    as

    severity. The preferred level of safety is OSL 3 and shall be procured as first choice when
    available from the manufacturer.
    se

    (i) Certification of breakaway support shall be collected from the manufacturer and
    submitted for Engineer approval prior to procurement. Certification documentation
    er

    shall confirm the Impact Speed Class, Energy Absorbing Type and Occupant Safety
    ov

    Level of the supplied luminaires.

    2 Related Equipment
    o

    (a) The column shall be rated to support Cloth Banners up to the length, width and height
    it

    as required in the Contract Documents. Each column shall be provided with a


    et

    240V earthed outlet rated for outdoor conditions in compliance with Section 21 Part
    m

    10.2.2 herein.
    (b) When required by the provisions of the Contract Documents, all poles, whether
    aluminium or steel in type, shall be supplied with a frangible element or
    breakaway base tested and certified to provide passive safety elements as to
    be in compliance with BS EN 12767, with special attention to National Annex
    (informative) to BS EN 12767:2007.

    3 Lighting System Requirements

    (a) Work related to the Passively Safe Lighting Column installation provided for in
    this specification shall include the supply, installation, testing, commissioning and
    putting into satisfactory operation all systems as required by the Contract Documents
    and the Specification.
    (b) Electrical connections for lighting columns shall be quick disconnect type at ground
    level, such that they provide for electrical isolation within 0.4 seconds upon impact of
    the lighting pole, and be furnished as required by BS EN 12767:2007 NA.8.
    QCS 2014 Section 06: Roadworks Page 23
    Part 15: Road Lighting

    (c) Prior to procurement, the Contractor shall provide shop drawings and supporting
    calculations required by the Specification, as well as the provision of all required
    supporting technical literature and samples in connection with the acceptance of
    proposed equipment approved by Ashghals authorized representative.
    (d) Due to the long lead times of such equipment, the Contractor shall order the poles
    within 1 week of shop drawing approval. The equipment supplied shall include all
    necessary items for a complete installation in accordance with the Specification and
    other Contract Documents in order to provide for specified luminaire operation.
    (e) Contractor shall provide all necessary accessories, wiring and equipment from lamp to
    base, feeder pillar to last luminaire, to complete a functional lighting system
    regardless of their inclusion in the Contract Documents.

    4 Lighting Equipment

    .
    (a) Lighting Columns

    l
    .l.
    (i) The Passively Safe Lighting Columns shall be procured from an Ashghal-

    rw
    approved manufacturer. The manufacturer shall submit no less than three
    references for contact on past performance, supplying previous installed
    contracts contact person, title, agency or company name, phone number and

    ta
    e-mail address to Ashghal Designs and Ashghal Operation and
    Maintenances authorized representatives as part of the approval process.
    qa
    (ii) Columns shall be constructed with their anchor bolts at no more than 100 mm
    above ground level. Anchor bolts furnished with the column support shall be
    as

    galvanized steel or stainless steel in type.


    se

    (b) Luminaire
    (i) Each luminaire fitted on the Passively Safe Lighting Columns shall meet all
    er

    illumination requirements set forth by Ashghal and the photometric specifics as


    outlined in the Contract Drawings.
    ov

    (c) Foundations
    o

    (i) Contractor shall submit the dimensions and specification of proposed


    it

    foundations for support of the Passively Safe Lighting Columns. Drawings


    et

    and specifications shall be prepared and sealed by a licensed structural


    engineer. The structural engineer shall provide certification that the proposed
    m

    foundation design supports the performance of the breakaway mechanism, and


    is designed properly to prevent movement or rotation in the surrounding soil.

    15.6.9 Decorative Lighting Columns

    1 Decorative lighting systems are non-standard, themed luminaire and pole styles. The
    luminaires range from ornate globes known as acorns to four-sided glass fixtures having a
    distinct character. The luminaires are mounted on the decorative lighting columns in a post-
    mounted arrangement or with a bracket arm. The Contractor shall coordinate final
    decorative lighting column and foundation placement with the Engineer to avoid problems
    related to the placement of trees, other street furniture and underground utilities.
    QCS 2014 Section 06: Roadworks Page 24
    Part 15: Road Lighting

    2 Each Decorative Lighting Column shall be anodized aluminium or galvanized steel as


    specified in the Contract Documents. Design of aluminium columns shall comply with
    BS EN 40, Part 6 and its incorporated references. Design of steel columns shall
    comply with BS EN 40, Part 5 and its incorporated references. Galvanized steel
    columns shall be supplied with aluminium cladding sufficient to provide the decorative
    features when detailed as such in the Contract Documents.

    3 Galvanized steel columns shall be supplied with aluminium cladding sufficient to


    provide decorative features when detailed as such in the Contract Documents.

    15.7 LIGHTING UNITS

    15.7.1 General

    .
    1 Road lighting luminaires (light fitting) shall be semi cut-off or cut off and side entry mounting

    l
    .l.
    type complete with bowl and integral control gear of rating 100W, 150W, 250W, or 400W,
    220-240V, 50Hz as specified in 15.9.

    rw
    2 All types of lamps shall be energy saving lamps (LED (light emitting diode), Induction lamps)
    manufactured according to International Electrotechnical Commission IEC or International

    ta
    Standards, and accepted or approved by Qatar Standards.
    qa
    3 The luminaires for roadway lighting shall be to IEC 60598 and shall be capable of achieving
    the lighting performance specification requirements set out in the Contract specification in
    as

    accordance with BS 5489 , EN 13201 and ANSI/IESNA RP-008 at the mounting heights
    identified within the Contract.
    se

    4 Luminaires shall be side entry mounting and semi cut-off or cut off type with integral control
    er

    gear for use with either 1x 100W, 1x 150W or 1 x 250W, 220- 240V, 50Hz, high pressure
    sodium tubular lamp of E-40 base. The E-40 lamp shall have a porcelain skin. The lamp
    ov

    supports shall ensure that the lamp position in respect of the optical system remains fixed
    throughout its operation. The body shall be made of die cast aluminium and shall be divided
    into two compartments.
    it o

    (a) The first compartment shall house the optical system with a pressed high purity one
    et

    piece aluminium reflector that is anodized and polished. The positioning of the reflector
    shall be such that should it nsslished. Tt lector
    m
    QCS 2014 Section 06: Roadworks Page 25
    Part 15: Road Lighting

    5 The accessories such as ballasts, starters, capacitors etc., shall be pre-wired and pre-
    assembled in the rear compartment on a detachable metallic gear tray fixed securely to the
    main body of the luminaire in such a way as to ensure effective earth continuity.

    6 Special care shall be taken to allow easy maintenance and quick replacement of the
    accessories and to minimise the risk of falling.

    7 The incoming cable feed terminal block and the earth-screw shall be fixed to either the gear
    tray or metallic compartment. A cable restraining device shall be mounted near the incoming
    terminal block. All metal parts shall be effectively earthed to the luminaire earth-screw that
    shall be readily visible and accessible once access is obtained to the rear compartment. The
    spigot entry socket of the luminaire shall be compatible with the column bracket and able to
    accept a 125mm long by 50mm diameter or adjustable from 42mm to 60mm diameter spigot.

    15.8 CONTROL GEAR

    l .
    .l.
    15.8.1 General

    rw
    1 All items of control gear shall be fitted with shrouds over all terminals to prevent accidental
    contact during lamp replacement or routine equipment maintenance. All control gear shall

    ta
    have a clearly marked circuit diagram to show its terminal connections in relation to all other
    qa
    components. Control gear (choke, capacitor, ignitor etc.) shall be suitable to withstand
    temperatures up to 86C and shall have a purpose made earth terminal. Internal connections
    shall be with heat resistant non-hydroscopic insulated stranded copper conductors, cleated
    as

    and with porcelain connectors.


    se

    2 Ballast (choke) shall be closed type polyester filled can. It shall be suitable for single phase
    voltage operation and silent in operation. All tappings shall be brought to suitably marked
    er

    standard terminals to which the lamp and supply connections shall be made.
    ov

    3 The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance
    of + or 10% of its marked value. Where non-metallic capacitors are offered these shall be
    supplied with a fixing band that shall not damage the capacitor when fitted. Where the
    o

    capacitor has an aluminium body it shall be provided with a separate earth terminal.
    it
    et

    4 Ignitors shall be mounted within the control gear compartment of the luminaire. Each ignitor
    m

    shall be fitted with a device that will detect the presence of a faulty lamp and automatically
    limit the generation of HV pulses. The ignitors shall be suitable for use with the lamp, ballast
    and power factor correction capacitor included within the control gear circuit.

    15.9 LAMPS

    15.9.1 General

    1 Lamps shall be energy saving lamps with clear tubular hard glass envelope with E-40 base
    suitable for use on 220 - 240 V, 50Hz, AC. Lamps shall be manufactured according to
    International Electrotechnical Commission IEC or International Standards, and accepted or
    approved by Qatar Standards.

    2 Energy saving lamps ( that have a minimum of 50% energy saving than the standard high
    pressure sodium vapour gas lamps)shall be:

    (a) High Intensity Discharge (HID) ,


    QCS 2014 Section 06: Roadworks Page 26
    Part 15: Road Lighting

    (b) Induction lamp types;


    (c) Light Emitting Diodes (LED)
    (d) and any other types of energy saving lamps accepted and approved by Qatar
    Standards .

    3 These lamps shall either have a built in or an external ignitor. Initial Lumen output for High
    Intensity Discharge (HID) lamps shall be no less than 4,500 lumens/watt for the 50 watt
    lamps, no less than 6,500 lumens/watt for the 70 watt lamps, no less than 12,500
    lumens/watt for the 100 watt lamps, no less than 17,500 lumens/watt for the 150 watt lamps,
    no less than 33,150 lumens/watt for the 250 watt lamps or no less than 48,000 lumens/watt
    for the 400 watt lamps,

    15.10 LIGHTING SYSTEM FOR UNDERPASSES

    l .
    15.10.1 General

    .l.
    rw
    1 The basis for the lanterns for use within both the lighting of the vehicular, pedestrian and
    animal underpasses pertains to lanterns designed for cornice surface mounting within each
    underpasses, complete with lamp, fuse and associated control gear. The lighting

    ta
    arrangement within each type of underpass shall be based on the use of a common lantern
    designed such that it can incorporate either a multi lamp or single lamp luminaire
    qa
    arrangement of a variable wattage.
    as

    15.10.2 Vehicular Underpass


    se

    1 The lanterns for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less
    than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
    er

    pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
    equivalent to the above wattages, complete with all materials as specified herein and in the
    ov

    Contract Documents and as required to provide a complete lighting installation.

    15.10.3 Pedestrian Underpass


    it o

    1 The lanterns for pedestrian underpasses shall consist of either 1x 70 Watt (no less than
    et

    6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
    sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps or energy saving lamps,
    m

    complete with all materials as specified herein and in the Contract Documents and as
    required to provide a complete lighting installation.

    15.10.4 Animal Underpass

    1 The lanterns for animal underpasses shall consist of either 1x 70 Watt (no less than 6,500
    lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium
    vapour luminaires, or Lumen/Watt-equivalent LED lamps, or energy saving lamps complete
    with all materials as specified herein and in the Contract Documents and as required to
    provide a complete lighting installation.
    QCS 2014 Section 06: Roadworks Page 27
    Part 15: Road Lighting

    15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses

    1 An underpass lantern shall consist of housing, front cover, reflector, socket, lamp, fuse,
    control gear, wiring, latches, screws, washers, pins and other parts composing a complete
    unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its
    optical housing shall have protection against the ingress of moisture and dust to degree IP55
    of IEC529 under all operating conditions.

    2 The optical seal which shall include the reflector mounting shall be adequate to maintain this
    degree of protection. With the exception of the reflector, lamp holder mounting and
    associated cable all other equipment shall be housed at the rear of the optical system and
    shall be readily accessible by access through the lantern front plate. These components shall
    include the lantern control equipment, associated cable and isolating fuse. The cable
    connections to the lampholder within the lantern shall be of the heat resistant type with
    silicon, glass fibre or other approved insulation.

    l .
    .l.
    3 The housing and front cover shall be made of stainless steel.

    rw
    4 The reflector shall be made of aluminium sheet of such grade and quality that :

    (a)
    ta
    The reflecting surface shall have a specular finish.
    qa
    (b) The reflecting surface shall have a dense protective coating of oxide not less than 1.2
    2
    mg/cm , applied by the anodic oxidisation process.
    as

    5 The reflector shall be of such material and construction as to provide low brightness and
    minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
    se

    non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.


    The seal of the optical system shall be accomplished with a gasket material that will not
    er

    deteriorate with age. This gasketing shall be continuous and shall ensure a heat and
    weatherproof seal. Suitably located knockouts to suit the cable conduit shall be provided in
    ov

    the housing. The lamp socket shall be provided with grips or other suitable means to hold the
    lamp against vibration.
    o

    6 The fascia plate of the lantern shall be manufactured from toughened glass protected, if
    it

    necessary due to a high incidence of vandalism by means of the manufacturers purpose


    et

    made wire mesh guard.


    m

    7 Between adjacent luminaries a stainless steel in fill plate shall be provided such that the
    whole assembly gives the appearance of a continuous cornice arrangement. The main sub
    circuit cables interconnecting each underbridge luminaire from the underpass isolating
    control box shall be routed between fittings within the luminaire or in fill plate by means of a
    purpose made cable tray arrangement. Within the structure the cabling shall be routed via
    galvanized steel conduit cast within the underpass walls and soffit of size suitable to
    accommodate the number of single core or multicore cables required whilst maintaining the
    stipulated space factor according to the relevant regulations. The cabling shall be either
    single core or multi core 6mm copper conductors within high temperature grade double
    insulated or flexible cable.
    QCS 2014 Section 06: Roadworks Page 28
    Part 15: Road Lighting

    15.10.6 Underbridge or Undercrossing Lantern and Installation

    1 The lantern for use within both the underbridge and undercrossing lighting shall be designed
    for directly mounting immediately above the kerb edge of the carriageway and shall be
    complete with lamp, fuse and associated control gear. The lighting arrangement shall be
    such that it can incorporate either a single lamp of a variable wattage.

    2 The underbridge or undercrossing lantern shall consist of housing, cover, reflector, socket,
    lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a
    complete unit. The lantern shall provide illumination, be mechanically strong and easy to
    maintain. Its optical housing shall have protection against the ingress of moisture and dust to
    degree IP55 of IEC529 under all operating conditions.

    3 The optical seal which shall include the reflector mounting shall be adequate to maintain this
    degree of protection. With the exception of the reflector, lamp holder mounting and

    l .
    associated cable all other equipment shall be housed at the rear of the optical system and

    .l.
    shall be readily accessible by access through the lantern front plate. These components shall

    rw
    include the lantern control equipment, associated cable and isolating fuse. The cable
    connections to the lampholder within the lantern shall be of the heat resistant type with
    silicon, glass fibre or other approved insulation.

    ta
    qa
    4 The housing and front cover shall be made of stainless steel.

    5 The reflector shall be made of aluminium sheet of such grade and quality that :
    as

    (a) The reflecting surface shall have a specular finish.


    se

    (b) The reflecting surface shall have a dense protective coating of oxide not less than 1.2
    2
    mg/cm , applied by the anodic oxidisation process.
    er

    6 The reflector shall be of such material and construction as to provide low brightness and
    ov

    minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
    non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.
    The seal of the optical system shall be accomplished with a gasket material that will not
    o

    deteriorate with age. This gasketing shall be continuous and shall assure a heat and
    it

    weatherproof seal. Suitably located knockouts to suit the conduit shall be provided in the
    et

    housing. The lamp socket shall be provided with grips or other suitable means to hold the
    lamp against vibration.
    m

    7 The fascia plate of the lantern shall be manufactured from toughened glass protected, if
    necessary due to a high incidence of vandalism by means of the manufacturers purpose
    made wire mesh guard.

    8 The main sub circuit cables interconnecting each underbridge or undercrossing luminaire
    from the underbridge or uncrossing isolating control box Within the structure the cabling shall
    be routed via galvanized steel conduit cast within the underbridge or structure walls and soffit
    of size suitable to accommodate the number of single core or multicore cables required whilst
    maintaining the stipulated space factor according to the relevant regulations. The cabling
    shall be either single core or multi core 10mm copper conductors within high temperature
    grade double insulated or flexible cable.
    QCS 2014 Section 06: Roadworks Page 29
    Part 15: Road Lighting

    15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps

    1 The control gear shall be designed to operate the lamp of the power rating and type indicated
    and it shall be able to start the lamp and control it continuously for ambient temperatures up
    to +55C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
    Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
    operating more than one lamp shall not be employed.

    2 The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance
    of +/ 10% of its marked value. Where non-metallic capacitors are offered these shall be
    supplied with a fixing band that shall not damage the capacitor when fitted and, if metallic,
    shall be provided with a separate earth terminal. The permitted operating temperature of the
    capacitor shall be marked on its case.

    3 Each lamp shall operate using only one choke and one capacitor. Any combination of two or

    l .
    more capacitors having the equivalent value of capacitance will not be accepted.

    .l.
    rw
    4 Chokes and capacitors shall comply with the relevant British Standard Specification or an
    acceptable International equivalent and shall be fully compatible with the complete
    associated operation lamp circuit.

    5 ta
    The ignitor for energy saving lamp shall be of the electronic solid state type and shall be
    qa
    arranged so that the ignitor circuit stops working after the lamp has started. It shall be totally
    enclosed. The circuit shall include a shunt capacitor to isolate the mains from high frequency
    as

    start pulses; this capacitor may also be used for power factor correction. The length of wiring
    between the ignitor and the lamp shall not exceed that recommended by the Manufacturer for
    se

    satisfactory lamp ignition and re-ignition of an extinguished lamp.


    er

    6 The control gear shall meet the following specifications:


    ov

    (a) It shall be suitable for 50 Hz, 240 V AC + 10% operation. .


    (b) It shall regulate the output power to 12% for the input voltage noted above.
    o

    (c) It shall have an overall power factor of at least 0.85 when operated under rated lamp
    it

    load.
    et

    (d) It shall operate the lamp without affecting adversely the lamp life and performance as
    m

    specified herein.
    (e) It shall withstand a 2500 V dielectric test between core and windings.
    (f) The choke shall be encapsulated in an approved resin compound and totally enclosed.

    7 The lamps for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than
    17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
    pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
    equivalent to the above wattages, complete with all materials as specified herein and in the
    Contract Documents and as required to provide a complete lighting installation.

    8 The lamps for pedestrian or animal underpasses shall consist of either 1x 70 Watt (no less
    than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
    sodium vapour luminaires, LED or energy saving lamps with Lumen/Watt-equivalent,
    complete with all materials as specified herein and in the Contract Documents and as
    required to provide a complete lighting installation.
    QCS 2014 Section 06: Roadworks Page 30
    Part 15: Road Lighting

    15.10.8 Underpass, Underbridge or Undercrossing Isolating Box

    1 At each underpass, underbridge or undercrossing location an isolating box assembly shall be


    provided to control and isolate the respective lighting. This assembly shall be constructed
    from either galvanized steel or stainless steel with a hinged vandal resistant lockable front
    cover complete with sealing gasket protection against the ingress of moisture and dust to
    degree IP54 of IEC529 under all operating conditions providing. A three phase mcb isolator
    shall be located within this housing to control the power supplies to each lighting sub circuit.
    The galvanized steel conduit providing the cabling routing within the structure shall be
    secured at the isolating box assembly by means of a locknut arrangement.

    15.11 LED LIGHTING UNITS

    15.11.1 Lighting Units

    l .
    .l.
    1 The degree of Ingress Protection provided by the luminaire, including the facility for a
    switching device, shall be rated at least IP66 in accordance with EN60529 (IEC529).

    rw
    Specification for degrees of protection provided by enclosures (IP code). This shall be
    certified by an independent IP testing and examination laboratory accredited by UKAS or
    equivalent accreditation body.
    ta
    qa
    2 The degree of Impact Protection provided by the luminaire against external mechanical
    impact shall be rated at least IK10 (metals and plastics) and IK08 (glass) in accordance with
    EN62262:2002 (IEC62262:2002) Degrees of protection provided by enclosures for electrical
    as

    equipment against external mechanical impacts (IK code). This shall be certified by an
    independent IK testing and examination laboratory accredited by UKAS or equivalent
    se

    accreditation body.
    er

    3 The luminaire assembly shall be tested and approved by an independent ENEC


    (European Norms Electrical Certification) national Certification Body and awarded the
    ov

    ENEC mark or equivalent international standards. Contractor shall provide verifiable


    certificate featuring contact information of Certification Body.
    o

    4 The luminaire shall be designed and suitably rated to ensure correct operation and
    it

    continuous trouble free service under the prevailing climatic conditions. The luminaire
    et

    shall be designed to withstand the effects of direct sun exposure during the day and dusty
    m

    weather conditions including the occasional sandstorm. The luminaire manufacturer shall
    guarantee the performance and life time claims of lumen maintenance and luminaire
    life of the luminaire under the stated climatic conditions.

    5 The luminaire housing shall be constructed from corrosion resistant marine grade
    aluminium alloy conforming to BS EN 1676, 1559-1, 1559-4 and 1706 and powder
    coated by an Akzo Nobel approved applicator, or equivalent, conforming to EN12206-1:2004
    Paints and varnishes. Coating of aluminium and aluminium alloys for architectural
    purposes. Coatings prepared from coating powder.

    6 The manufacturer shall supply a RAL colour chart depicting the range of powder coat colours
    available for the external finish of the luminaire. Luminaire colour shall be specified at the
    time of ordering.

    7 The optical assembly and control gear components shall be integral to the luminaire
    body.
    QCS 2014 Section 06: Roadworks Page 31
    Part 15: Road Lighting

    8 For maintenance the luminaire shall allow tool-less access and incorporate quick
    disconnect features and universal fittings. All component parts shall be easily accessible and
    securely mounted to prevent accidental falling and manufactured from corrosion
    resistant materials or treated to prevent corrosion. The luminaire cover shall include an
    optional security feature to enable locking by means of a tool. The cover shall also
    incorporate a safety switch to disconnect power on opening and any upward rising
    hinged canopy shall be secured in an open position by means of a brace to prevent
    accidental closing.

    9 The luminaire shall be procured from a prominent luminaire manufacturer that publishes
    product specifications measured in compliance with the IEC/PAS performance
    requirements or equivalent.

    10 The complete luminaire shall be at least 98% recyclable.

    l .
    11 The luminaire shall be vandal resistant. The ingress of insects through any system vent or

    .l.
    aperture shall be prevented by means of a filter.

    rw
    12 The luminaire shall be compliant with the Waste Electrical and Electronic Equipment
    (WEEE) Directive (2002/96/EC) and the Restriction of the use of certain Hazardous

    ta
    Substances in electrical and electronic equipment (RoHS) Directive (2002/95/EC).
    qa
    13 Each luminaire shall have a barcode securely attached internally within the gear
    compartment identifying the luminaires reference/catalogue number, total wattage and
    as

    LED current setting and other attributes as required by Ashghal and as required of the
    Enterprise Asset Management System (EAMS). The barcode type shall be compatible with
    se

    the handheld device authorized for use by Ashghal.


    er

    14 All internal and external wiring of the luminaire shall comply with EN60598-1:2008
    Luminaires, General requirements and tests and shall be flexible and suitably rated and
    ov

    insulated to withstand the voltages and temperatures encountered in service.

    15 Any luminaire wiring passing through metal shall have suitable grommets or otherwise be
    o

    protected to avoid abrasion of the insulation.


    it
    et

    16 All luminaire terminals and supply connections shall comply with EN60598-1:2008. The
    conducting material of any terminal block shall be made of brass and shall have screw down
    m

    plates bearing on the wires. Terminals where screws bear down directly on wires will not be
    acceptable.

    17 Luminaires shall be earthed in accordance with EN60598-1:2008. An earth terminal forming


    part of the luminaire body shall be provided. All parts of an earth terminal shall be made of
    brass.

    18 Luminaires shall be future proofed by allowing the LED modules to be upgraded easily in
    situ, as LED efficiency improves. Upgrading of luminaires, or replacement of faulty
    components, with manufacturer approved components shall not have any detrimental
    impact whatsoever on the luminaires manufacturer warranty. Prototypes shall not be
    accepted.

    15.11.2 Lighting Performance


    QCS 2014 Section 06: Roadworks Page 32
    Part 15: Road Lighting

    1 Highway luminaires shall be suitable to achieve the lighting class standards as detailed in the
    Qatar Design Management Manual, as referenced in ANSI/IESNA RP-008, and as applicable
    to Primary, Secondary and Tertiary roads in The State of Qatar, under the control of Ashghal
    and other areas as required.

    2 The luminaire shall be compliant with EN60598-1:2008 Luminaires. General


    requirements and tests, and EN60598-2-3:2003 Luminaires. Particular requirements.
    Luminaires for road and street lighting.

    3 The luminaire shall be able to restrict glare and control obtrusive light in accordance with the
    full cut-off and semi cut-off concepts and associated luminous intensity classes defined in
    ANSI/IESNA RP-008 or an equivalent, Ashghal-authorized standard. Individual project
    contract drawings and design specifications shall detail the luminous intensity class
    requirement.

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    4 The luminaire shall control light output to limit light pollution and minimise sky glow in

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    accordance with Commission Internationale de l'clairage (CIE) 126-1997 Guidelines for

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    minimizing sky glow and meet the requirements therein for maximum permissible
    upward light output ratio (ULOR) expressed as the percentage of luminous flux
    acceptable in each of four different Environmental Zones.

    ta
    qa
    5 The efficacy of the luminaire is given by the total lumen output divided by the power into the
    system and shall be equal to or greater than 100 lm/w (lumens per watt) operating within the
    climate conditions as stated herein. The contractor shall obtain a statement from the
    as

    luminaire manufacturer declaring that quoted performance figures correspond to the stated
    ambient air temperature and ensure that the specifics of operating in the Qatar environment
    se

    are written into any applicable section of the manufacturers warranty agreement.
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    15.11.3 Thermal Management


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    1 The luminaire shall be capable of withstanding severe climate conditions, as stated in


    Section 21, Part 1. General Provisions for Electrical Installation, clause 1.1.14.
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    2 As a minimum, manufacturers shall use 50 C as the night time ambient temperature


    it

    with 95% humidity.


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    3 The luminaire shall be designed to provide satisfactory heat dissipation for any powered
    m

    component parts and maintain safe operating temperatures at all times under the stated
    climatic conditions. Heat dissipation shall be by passive thermal management, active or
    mechanical cooling is not acceptable.

    4 All materials used in the luminaire shall be resistant to high temperature UV (ultra violet)
    exposure and be 90% UV-stable.

    5 The luminaire shall incorporate a passive thermal management system, active cooling such
    as fan assisted systems will not be accepted. The manufacturer shall demonstrate that the
    luminaire is suitable for continuous operation in the Qatar environment. Within the stated
    climate conditions the LED junction temperatures shall be shown to remain within the range
    required to limit the risk of accelerated degradation of the LEDs based on the stated life
    expectancy of the luminaire.
    QCS 2014 Section 06: Roadworks Page 33
    Part 15: Road Lighting

    6 Junction temperature cannot be measured directly and must be derived using calculation
    formulae and temperature measurements read from a thermocouple device attached to a
    series of defined reference points (thermal pads) on the outer casing (package) of the LED.
    Thermal verification testing is carried out as a laboratory based operation with ambient
    conditions simulated.

    7 The luminaire manufacturer shall submit a statement declaring that quoted LED
    performance figures correspond to the stated ambient air temperature and ensure that the
    specifics of operating in the Qatar environment are written into any applicable section
    of the warranty agreement.

    8 The maximum allowable ambient temperature for the LED lighting shall be stated, in
    which the LED lighting can operate without adversely affecting any components life,
    luminaire light output or colour stability. This shall take into consideration the maximum case
    temperature of the driver and the design LED junction temperature.

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    9 Manufacturers shall state the predefined critical temperature level at which the dim down and

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    switch off protection events occur and relate to junction temperature and ambient
    temperature. The luminaire shall be constructed in such a way that this protection
    method shall not occur during climate conditions stated within this specification.

    ta
    qa
    15.11.4 Testing

    1 LED Luminaire lighting performance shall be measured using an independent


    as

    photometric testing laboratory accredited by UKAS or equivalent accreditation body. The test
    procedure and measurements shall be carried out in accordance and compliance with
    se

    IES_LM-79-08 Approved Method: Photometric Measurements of Solid State Lighting


    Products. The photometric test report shall list all significant data for each SSL product
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    tested together with performance data and also pertinent data concerning conditions of
    testing, type of equipment, and reference standards. The photometric test procedure shall
    ov

    also be used to calculate correction factors in allowance of the stated climate conditions.

    2 Photometric data for each luminaire optical setting shall be available in electronic file
    o

    format in accordance and compliance with IES_LM-63-02 Standard File Format for
    it

    Electronic Transfer of Photometric Data and Related Information and EN13032-


    et

    1:2004+A1:2012 Light and lighting. Measurement and presentation of photometric data of


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    lamps and luminaires. Measurement and file format. The photometry files shall be
    compatible for use with industry recognised road lighting design software packages or as
    requested by Ashghal and include applied correction factors specific to the declared
    ambient conditions.

    3 Lighting performance of the LED luminaire in terms of design spacings relative to a


    specified road lighting class should be comparable to a modern HID lamp based
    luminaire with similar lumen output.

    4 The luminaire manufacturer shall submit a statement declaring that quoted photometric
    performance figures correspond to the stated ambient air temperature (not LED junction
    temperature) and ensure that the specifics of operating in the Qatar environment are
    written into any applicable section of the warranty agreement.

    5 The luminaire shall be tested in accordance and compliance with EN62471:2008


    (IEC62471:2006) Photobiological safety of lamps and lamp systems or an equivalent
    standard. Any assumptions made during testing shall be clearly stated.
    QCS 2014 Section 06: Roadworks Page 34
    Part 15: Road Lighting

    6 The luminaire LED light source shall be tested in accordance and compliance with
    IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources. The
    LM-80-08 test report produced for the LED light source shall meet the eligibility
    criteria necessary for submission to the U.S Department of Energy (DOE) Energy Star
    Program Requirements for Solid State Lighting Luminaires.

    15.11.5 In Situ Temperature Measurement Test (ISTMT)

    1 In order to relate the LM-80 test to the luminaire and stated climatic conditions, testing shall
    be completed that simulate this application. This shall be achieved by In Situ
    Temperature Measurement Test (ISTMT) which follows ANSI/UL 1598-2004 Luminaires.

    2 The luminaire manufacturer shall provide a written undertaking to the satisfaction of


    Ashghal\s authorized Engineer to warranty the materials and performance as follows:

    .
    (a) LED arrays shall have a written warranty for a minimum of 50,000 hours at the ambient

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    temperature specified herein and shall be replaced on a one for one basis upon failure.

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    An LED array will be deemed to have failed when:
    (b) equal to or greater than 10% of the individual LED chips in an array has failed or an
    array does not provide the required lumen maintenance (L70).
    (c) ta
    Drivers shall have a written warranty for a minimum 50,000 hours and shall be
    qa
    replaced on a one for one basis.
    (d) Luminaire housing and all external components such as; lenses, gaskets & fastenings
    as

    and the fixture finish shall have a written warranty for a minimum twenty (20) years
    against the deterioration of, but not limited to, mechanical failure, UV degradation,
    se

    corrosion, yellowing, blistering, chalking, cracking, peeling or fading.


    (e) The Warranty shall be transferable without limitations in its entirety to Ashghal, Public
    er

    Works Authority, Qatar.


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    3 Equivalent or more onerous standards can be proposed, by the manufacturer, as an


    alternative to the detailed standards, with the exception of Qatar documents. Evidence shall
    o

    be submitted detailing the equivalent or more onerous sections that deviates from the
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    intended standard.
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    15.11.6 Control Gear


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    1 The luminaire control gear (driver) shall be produced by a prominent manufacturer of


    semiconductor components and comply with IEC 62384 DC or AC supplied electronic
    control gear for LED modules - Performance requirements. The manufacturer shall
    confirm that the packaged driver assembly is fabricated from high quality integrated
    circuit components including long-life electrolytic capacitors and provide data relating to the
    reliability of the device, in the climatic conditions stated in this specification.

    2 The drivers shall be encapsulated / potted and Class II double insulated (IEC61140) and
    have a minimum energy efficiency of 85% and power factor 0.9 (full load). The control gear
    shall feature Surge Protection Device (SPD) for lightning strikes (IEC62305), short-circuit
    protection and transient overvoltage protection (IEC61643-1 / IEC61000-4-5).
    QCS 2014 Section 06: Roadworks Page 35
    Part 15: Road Lighting

    3 The LED drivers shall be housed on a removable gear tray accessible with the luminaire
    cover open and be compatible with the Qatar power supply. The supply cable shall pass
    through the mounting post, or bracket, directly into the luminaire through an M20 cable gland
    located at the base of the luminaire mounting socket.

    4 For protection in the event of temperatures reaching predefined critical levels, both
    LEDs and drivers shall have thermal protection, which will initially dim down and
    eventually switch off the light. Manufacturers shall state the predefined critical
    temperature level at which the dim down and switch off protection events occur and
    relate to junction temperature and ambient temperature. The luminaire shall be
    constructed in such a way that this protection method shall not occur during climate
    conditions stated within this specification.

    5 The driver system shall be compatible with Lighting Control Systems / Lighting
    Management Systems (LMS), using both analogue (1-10V) and Digital Addressable

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    Lighting Interface (DALI) protocols including WiMAC or other similar Ashghal-approved

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    driver system. The driver system shall also be capable of being configured for

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    single, and multi-stage, stand-alone dimming configurations when not connected to a
    CMS.

    6
    ta
    The drivers shall be programmable and permanently configured to operate under the
    principle of constant flux output or maintenance factor harvesting or similar, Ashghal-
    qa
    approved configuration method. During this process light output is initially dimmed to an
    equivalent end of life level value and then the operating current is gradually increased
    as

    throughout service life to compensate for lumen depreciation and maintain a constant
    lighting level. The advantage of this system is to give energy savings and improve LED
    se

    life and reliability. The manufacturer shall provide details of how this facility is maintained
    following replacement of a faulty driver or LED array.
    er

    7 The driver shall be capable of operating within the climate conditions previously
    ov

    described and shall have documentation and certification supporting the claimed
    minimum life expectancy of 50,000 hours in the stated conditions within this
    specification.
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    8 The driver manufacturers device data sheet will provide specification details and the
    et

    maximum permissible ambient temperature range in which the driver can operate (free air
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    convection) at the defined driver current. The luminaire manufacturer shall


    demonstrate that the LED driver is suitable for continuous operation in the Qatar
    environment. Within the stated climate conditions the driver compartment enclosure shall be
    shown to remain within the range required to limit the risk of driver failure during
    operation based on the stated life expectancy of the luminaire.

    9 The luminaire manufacturer shall submit a statement declaring that quoted driver
    performance figures correspond to the stated ambient air temperature and ensure that the
    specifics of operating in the Qatar environment are written into any applicable section
    of the warranty agreement.

    10 The luminaire shall conform to CE marking directives including the European


    Electromagnetic Compatibility (EMC) Directive EN 61000-3-2:2009 (IEC 61000-3-
    2:2009) Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic
    current emissions (equipment input current 16 A per phase)
    QCS 2014 Section 06: Roadworks Page 36
    Part 15: Road Lighting

    15.11.7 LED Lamps

    1 The LEDs shall be produced by a Ashghal Approved manufacturer of solid state lighting
    (SSL) components and comply with the related standards and guidelines set by the
    Illuminating Engineering Society of North America (IESNA) and the JEDEC Solid State
    Technology Association and approved by Qatar Standards.

    2 The light source is required to control light output with the aim of optimising luminaire
    performance and efficiency in relation to the specific lighting application. The luminaire, or
    luminaire series, shall provide the facility for varying luminous flux output ranging from 5klm
    up to at least 40klm using an appropriate number of LEDs and a suitable control method for
    each different lumen package.

    3 The luminaire LED module shall comply with International Electrical Commission
    Publicly Available Specification IEC/PAS62717 LED modules for general lighting

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    Performance requirements.

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    4 The LED arrays shall be capable of operating within the climate conditions previously
    described and shall have documentation and certification supporting the claimed minimum
    life expectancy of 50,000 hours at L70 in the stated conditions as within this specification.

    5 ta
    Technical details shall be provided of the light source optical system and range of optics or
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    optical settings available for each model of luminaire including performance
    characteristics. The optical system is required to control light output with the aim of
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    optimising luminaire performance and efficiency in relation to the specific lighting


    application. The system should meet the lighting requirements of most rights of way
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    types and configurations and maximise the light output ratio (LOR) of the luminaire.
    er

    6 The inadvertent failure of any LEDs during the life of the luminaire shall not bring about any
    reduction in uniformity of light output. Therefore, the multi-layer method of light distribution
    ov

    shall take precedence over multiple spot methods.

    7 Diffuser systems may be required for some lighting applications to eliminate the effect of
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    multiple-source shadows.
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    et

    8 Chromaticity tolerance and associated colour consistency of luminaire LED modules


    shall be measured in terms of the CIE 1931 chromaticity diagram and the CCT
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    quadrangles defined by the American National Standards Institute (ANSI) C78.377-


    2008 Specifications for the Chromaticity of Solid State Lighting Products for Electric Lamps.
    The ANSI quadrangle is made up by smaller quadrangles, commonly referred to as bins. The
    x y chromaticity components of each LED module shall be enclosed by one bin and the bin
    size shall not exceed a 4-step MacAdam ellipse. The binning process shall be in compliance
    with National Electrical Manufacturers Association (NEMA) SSL 3:2010 High-Power
    White LED Binning for General Illumination.

    9 The chromaticity shift shall be measured and reported in accordance with IES_LM-80-08
    Approved Method: Measuring Lumen Maintenance of LED Light Sources.
    QCS 2014 Section 06: Roadworks Page 37
    Part 15: Road Lighting

    10 For highway lighting the Correlated Colour Temperature (CCT) of the light emitted from the
    luminaire shall be in the range 4000K with a Colour Rendering Index (CRI) of 60. The
    manufacturer shall state the CCT ranges available with a 275K warranted window. The CCT
    and CRI shall include the effects of colour shift over the life of the luminaire. Other CCT
    ranges may be applicable to individual projects and manufacturers shall be notified as
    required.

    11 Lumen maintenance (L) is the luminous flux emitted by the light source at any specified time
    during its operational life and is expressed as a percentage of the luminous flux
    emitted at the start of life (L%). The rated lumen maintenance life of the LED light source
    shall not exceed L70, or 30% lumen depreciation at the specified temperature conditions.

    12 The luminaire manufacturer shall define the estimated service life of the light source in terms
    of operating hours and rated lumen maintenance. The minimum standard expected shall be
    50,000 operating hours at L70 at the temperature conditions specified herein.

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    13 The method of deriving rated lumen maintenance life beyond the limits of lumen

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    maintenance determined from actual measurements shall be demonstrated. The method for
    projecting the lumen maintenance of LED light sources from the data obtained by the
    procedures found in IES document LM-80-08 shall be in accordance and compliance

    ta
    with IES_TM-21-11 Projecting Long Term Lumen Maintenance of LED Light Sources.
    qa
    14 In combination with rated life predications the reliability of the LED modules shall also be
    expressed in terms of the percentage (fraction) of failures in accordance with IEC/PAS
    as

    62722-2-1:2011 Luminaire performance - Part 2-1: Particular requirements for LED


    luminaires. The failure fraction (Fy) corresponds to the percentage of LEDs that fail
    se

    before end of rated life. This failure fraction expresses the combined effect of all
    components of a module including mechanical, as far as the light output is concerned. The
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    effect of the LED could either be less light than claimed or no light at all.
    ov

    15 The failure fraction shall also be expressed in terms of its component parts, gradual failure
    fraction (By) and abrupt failure fraction (Cy). The reliability curve relative to operating hours is
    calculated using statistical formulae and data gathered under test conditions during luminaire
    o

    monitoring periods.
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    et

    16 Luminaire maintenance factors (LMF) to follow model used in BS5489-1:2003+A2:2008


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    Annex D Table D1 with figures extrapolated to extend cleaning cycle interval up to 6


    years and also adjusted to take account of environmental conditions specified herein.

    17 Lamp flux maintenance factor (LFMF) shall be calculated by the manufacturer in accordance
    with calculated lumen depreciation relative to a predefined cleaning cycle interval. Currently
    the perceived cleaning interval is biannually due to the intense dust laden atmosphere.

    15.11.8 Quality Criteria for LED Lighting

    1 Manufacturers shall submit data in accordance with IEC/PAS 62717 Performance


    requirements LED modules for general lighting and IEC/PAS 62722 Performance
    requirements LED luminaires for general lighting.
    QCS 2014 Section 06: Roadworks Page 38
    Part 15: Road Lighting

    15.11.9 LED manufacturers data

    1 Manufacturer shall provide a standardised set of quality criteria, measured in


    compliance with the appropriate standard. The performance claims shall be matched against
    traceable data. The performance data required is summarised below and shall be headed
    Quality Criteria:

    (a) Rated input power (in W)


    (b) Rated luminous flux of the luminaire (in lm)
    (c) luminaire efficacy (in lm/W)
    (d) Luminous intensity distribution
    (e) Photometric code
    (i) Rated Colour Rendering Index (CRI)

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    (ii) Correlated Colour Temperature (CCT in K)

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    (iii) Rated chromaticity co-ordinate values (initial and maintained)
    (iv) Maintained luminous flux
    (f)
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    Rated life (in h) of the module and the associated rated lumen
    qa
    (g) maintenance (Lx)
    (h) Failure fraction (Fy), corresponding to the rated life of the module in the
    as

    (i) luminaire
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    (j) Ambient temperature (ta) for the luminaire


    (k) Power Factor
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    (l) Intensity Distribution


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    (m) Drive Current


    (n) Optical Risk Group
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    2 This data shall be submitted on an Ashghal-approved form. Forms shall be submitted to


    et

    Ashghal for approval prior to submitting data for consideration. Further data shall be
    provided to evidence compliance with all aspects of this specification. Additional data shall be
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    provided as and when requested by Ashghal.

    15.12 OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION

    15.12.1 General

    1 The basis for the lanterns for use on the overhead sign gantries or bridges for the illuminating
    of overhead guide signs mounted on the sign support structure or on the gantry sign walkway
    supported on the gantry sign support brackets. The lanterns shall be complete with lamp,
    isolating fuse and associated control gear.
    QCS 2014 Section 06: Roadworks Page 39
    Part 15: Road Lighting

    15.12.2 Sign Gantry Lantern

    1 The lanterns shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
    lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
    lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
    33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
    socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
    composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
    75% of the initial luminous flux.

    2 The lantern shall provide efficient illumination, be optically sealed, mechanically strong and
    easy to maintain.

    3 The reflector mounting, wiring terminals and control gear components shall be readily
    accessible. When closed for operation, the optical assembly shall be sealed to provide

    l .
    protection against the ingress of moisture and dust to degree IP55 of IEC529 under all

    .l.
    operating conditions.

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    4 The seal between the refractor and the housing shall be adequate to maintain this degree of
    protection. The refractor shall be held in such a manner as to allow for expansion and

    ta
    contraction of the refractor. Cable connections to the lamp holder within the lantern shall be
    qa
    of the heat resistant type with silicon, glass fibre or other approved insulation.

    5 The optical system shall consist of a hydroformed aluminium primary beam reflector which
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    shall be precisely profiled and contoured to distribute light across the inner surface of the
    refractor. The prismatic refractor shall be of moulded borosilicate thermal shock-resistant
    se

    glass. The inner surface shall have an intricate array of prisms to direct light across the face
    of the sign. The outer surface shall be smooth to facilitate self-cleaning. The reflector shall be
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    of a retro-dispersing type designed to eliminate the halo of excessive luminance to assure


    more uniform sign luminance.
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    6 The terminal board shall be located beneath the reflector at the conduit entry and shall
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    accommodate 10 mm electric cables.
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    7 The reflector shall be fastened to the housing by means of a minimum of four stainless steel
    et

    screws with keyhole slot to facilitate easy removal and replacement. Levelling pads are to be
    provided on the inside and bottom of the main housing to permit accurate installation.
    m

    8 There shall be mounting within of the stainless steel housing to permit the lantern to be
    mounted directly to the supporting structure.

    9 The refractor shall be form-fitted to the stainless steel door frame and shall have a single
    piece gasket with a sealing pad to effectively seal the assembly and housing. The assembly
    shall be fastened to the housing by means of separable hinges at the front and spring
    tempered, stainless steel at the rear. The lamp socket shall be provided with grips or other
    suitable means to hold the lamp against vibration.

    10 The terminals of all ballasts, capacitors and control gears shall be shrouded.

    11 Each sign lighting system shall be subject to the approval of the Engineer. Particular attention
    shall be given to the mechanical strength of all components, and to the security of their
    method of the sign supports.
    QCS 2014 Section 06: Roadworks Page 40
    Part 15: Road Lighting

    15.12.3 Sign Gantry Lantern Control Gear and Lamps

    1 The control gear shall be designed to operate the lamp of the power rating and type indicated
    and it shall be able to start the lamp and control it continuously for ambient temperatures up
    to +55C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
    Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
    operating more than one lamp shall not be employed.

    2 The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance
    of + or 10% of its marked value. Where non-metallic capacitors are offered these shall be
    supplied with a fixing band that shall not damage the shell and be provided with a separate
    earth terminal. The permitted operating temperature of the capacitor shall be marked on its
    case.

    3 Each lamp shall operate using only one choke and one capacitor. Any combination of two or

    .
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    more capacitors having the equivalent value of capacitance will not be accepted.

    .l.
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    4 Chokes and capacitors shall comply with the relevant British Standard Specification or an
    acceptable International equivalent and shall be fully compatible with the complete
    associated operation lamp circuit.

    5 ta
    The control gear shall meet the following specifications:
    qa
    (a) It shall be suitable for 50 Hz, 240 V AC + 10% operation.
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    (b) It shall regulate the output power to 12% for the input voltage noted above.
    (c) It shall have an overall power factor of at least 0.85 when operated under rated lamp
    se

    load.
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    (d) It shall operate the lamp without affecting adversely the lamp life and performance as
    specified herein.
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    (e) It shall withstand a 2500 V dielectric test between core and windings.
    (f) The choke shall be encapsulated in an approved resin compound and totally enclosed.
    it o

    6 The lamps shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
    et

    lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
    lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
    m

    33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
    socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
    composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
    75% of the initial luminous flux.
    QCS 2014 Section 06: Roadworks Page 41
    Part 15: Road Lighting

    15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables

    1 At each sign gantry location an isolating (safety) shall be provided at walk way level of the
    structure. It shall be fabricated galvanized steel complete with a vandal resistant hinged
    access door. A three phase mcb isolator shall be located within this housing to control the
    power supplies to each lighting sub circuit. The galvanized steel conduit, secured to the
    gantry structure by means of purpose made saddles to suit the size of conduit, providing the
    cabling routing within the structure shall be secured at the isolating box assembly by means
    of a locknut arrangement. The size of the conduit shall be suitable to accommodate the
    number of single core or multicore cables required whilst maintaining the stipulated space
    factor according to the relevant regulations. A 3-phase mcb isolator shall be located within
    the isolating (safety) switch to control the lighting sub circuit upon each gantry structure. The
    cabling shall be either single core or multi core 10mm copper conductors within high
    temperature grade double insulated or flexible cable.

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    15.13 PHOTO ELECTRIC CONTROL CELL

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    15.13.1 General

    1 Photo electric control cells shall comply with the requirements of BS 5972 and offer a Class II
    ta
    protection from electric shock as defined in IEC 60598.
    qa
    2 Unit must be completely weatherproof, hermetically sealed against the ingress of moisture. It
    shall be resistant to vibration or change in temperature. It shall be housed in a strong impact
    as

    resistant low profile translucent housing, the surface of which shall be non- oxidizing and
    impervious to deterioration.
    se

    3 The photo electric control unit (PECU) shall be guaranteed for a period of not less than six
    er

    years, failures within that period of time to be replaced free of charge.


    ov


    4 They will be capable of working in an ambient temperature of up to + 60 C.

    5 The operation level should be preset to ON 80/100 Lux the ratio of ON to OFF should be
    o

    approximately 1:2. There shall be no means of manual adjustment to the PECUs calibration
    it

    and it shall not need to be orientated to operate as required.


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    m

    6 There should be a minimum 15 second delay to prevent the unit from functioning due to short
    period high illumination such as lightning etc.

    7 The power supply to the PECU shall be 240V 50Hz. A.C with a contact output rating of 30A at
    240V (resistive).

    8 The PECU and associated relay or switching device shall have pre matched responses and
    housed in the same envelope. The contact rating shall be 1500-Watts (1800 V.A) and should
    be fitted with a snap action to prevent chatter. In the case of the load to be switched then the
    PECU can switch directly, a contactor shall be used.

    9 The photocell shall be located within the road lighting feeder pillar such that it can be easily
    removed. It shall be housed within a small compartment with an acrylic fascia plate set into
    the surface of the feeder pillar for the satisfactory operation of the photocell. The control
    circuitry for the correct switching of the road lighting will be housed within the adjacent feeder
    pillar. The associated specification requirements will be dealt with within that section of the
    specification.
    QCS 2014 Section 06: Roadworks Page 42
    Part 15: Road Lighting

    10 The upper LED luminaire cover shall have the facility for installation and wiring of one of the
    following devices: an integral miniature photocell, NEMA socket (detachable photocell),
    telemetry device. This facility shall be included within the IP testing.

    15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS

    15.14.1 General

    1 Cutouts in columns shall be phenolic moulded, three phase, and suitable for looping two 4
    Core 25 mm XLPE/SWA/PVC cables.

    2 Cutouts shall :

    (a) Incorporate miniature circuit breakers complying to BS EN 60898 with a minimum


    breaking capacity of 4kA.

    l .
    .l.
    (b) Be of the combined single phase and neutral type.

    rw
    (c) Incorporate an earth terminal.
    (d) Be suitable for concentric or PVC armoured cables of up to 25mm2 cross-sectional
    area with capacity for looping in and out.
    (e) Have all metal parts tinned. ta
    qa
    (f) Be provided with a minimum of 2 fixing screws.
    as

    (g) Be manufactured from material which is non-hygroscopic and non-tracking.

    3 Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for the
    se

    use of miniature circuit breakers 6 A, 10A or16 A ratings, selected from the Table 15.2 below:
    er

    Table 15.2
    Ratings of Miniature Circuit Breakers
    ov

    Wattage 50W 70W 100W 150W 250 W 400 W

    For 1 Lamp 6 6 6 6 10 10
    it o

    For 2 Lamps 6 6 6 10 16 16
    et

    4 The cutouts shall comply with the 16th Edition of the IEE Wiring Regulations.
    m

    5 A cutout used as a means of isolation shall have the facility for padlocking.

    6 The service cutout shall have a moulded enclosure, offering a minimum protection of IP22,
    capable of withstanding severe impact.

    7 Separate terminals shall be provided for live, neutral and earth conductors complete with
    terminal shields to prevent accidental contact with all live conductors.

    8 Cutouts shall be sized to accommodate the designated cables, but with a minimum of
    25mm2 cables.

    9 Cable armouring shall be bonded as an integral part of the cutout, and complete with cable
    armour clamp shrouds.

    10 The cutout shall be suitable for mounting on a wooden backboard or DIN rails.
    QCS 2014 Section 06: Roadworks Page 43
    Part 15: Road Lighting

    11 Where there is a requirement for the use of an isolator they shall incorporate in-built fused
    loop terminals for the feeds to signs, bollards etc.

    12 All isolating devices shall be double pole for single-phase systems and four poles for three
    phase systems.

    13 All isolators shall be rated to suit the local environmental conditions of Qatar where these
    differ from those stated in BS EN 60947-3

    15.15 FEEDER PILLAR

    15.15.1 General

    1 Road lighting feeder pillars shall be totally enclosed weatherproof with fibreglass reinforced
    polyester cabinet of ground mounting type complete with accessories suitable for mounting

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    outdoor..

    .l.
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    15.15.2 Cabinet

    1 The feeder pillar cabinet, unless previously approved by the Engineer, shall be of fibreglass-

    ta
    reinforced polyester and ultra violet ray resistant. The cabinet surface shall be totally weather
    qa
    and corrosion resistant with a completely smooth exterior. The outer 0.5mm - 1.0mm should
    consist of pure polyester. The colour of the cabinet shall be grey. The colour shall be
    completely light stabilised and impregnated from the surface through the thickness of the
    as

    material.
    se

    2 Pillars shall be ground mounting type by means of a steel frame with concrete foundation.
    The cabinet shall have a base frame with a minimum ground clearance of 200mm between
    er

    the body and the mounting area (bottom). The base frame shall have at least four holes to
    bolt down the pillar to the concreted steel frame. The cabinets base frame shall be
    ov

    removable. The feeder pillar shell shall incorporate lifting devices for the safe movement of
    the feeder pillar.
    o

    3 The cabinet top (canopy) shall be arranged so as to prevent the ingress of rainwater and
    it

    provide air circulation.


    et
    m

    4 The cabinet shall be provided with a front door complete with internal hinges and fixing
    screws fixing at top and bottom. A tamper proof lock will be provided centrally and all locks
    shall operate by a standard master key. Two keys for each pillar shall be provided. The door
    closing will have a perfect weatherproofing arrangement. The enclosure shall have a
    designated IP rating of IP54 in accordance with IEC 60529.

    5 Approximate cabinet size shall be 1000mm high by 620mm length by 300mm width..

    6 Natural ventilation shall be provided to limit the temperature rise to the manufacturers
    recommendations. Such ventilation shall not reduce the stated IP rating of the cabinet and
    shall be screened to prevent the entry of vermin. Where recommended by the manufacturer
    dust filters shall be provided.

    7 A data plate shall be fixed to the inside of the pillar detailing information as deemed
    necessary by the PWA and/or the Engineer.
    QCS 2014 Section 06: Roadworks Page 44
    Part 15: Road Lighting

    8 Detailed distribution board schedules are to be provided within the each feeder pillar these to
    be located on the inside of the cabinet and stored in a weather protected plastic pocket
    securely fixed to the shell of the housing.

    15.15.3 Components of Feeder Pillars

    1 1 No. 200Amp mains breaker (MCCB) of three phase 415V - interrupting capacity according
    to BS 3871:
    240V 85kA
    415V 35kA
    A facility to lock off the assembly in the open position shall be provided.
    2 1No. 200Amp 4 pole magnetic contactor, three phase with coil voltage of 240V within an IP
    54 enclosure. The contacts of the contactor shall be fitted with a snap action to prevent
    chatter.

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    .l.
    3 A control circuit shall be provided connected to the control coil of the contactor. The circuit
    shall be protected by means of a 4A HRC control fuse within a weatherproof enclosure. The

    rw
    control circuit shall be such that in the event of a failure of the photocell control unit a time
    switch identified below will override the operation. In addition a manual override switch shall

    ta
    be provided to operate the road lighting at times outside the periods during which the lights
    are normally operational.
    qa
    4 The time switch shall be a 24-hour dial time switch motor driven single phase 30 Amp. 220 -
    240V 50 Hz. with a clock accuracy of + or 5minutes/year and shall have a 48-hour
    as

    synchronous spring reserve to maintain clock operation and output switching during power
    supply failure or disconnection. Time switch should be protected with a HRC fuse or MCB.
    se

    Arrangement for connecting a photoelectric control switch shall also be made within the pillar.
    er

    5 A 3-phase MCB metal clad or plastic distribution board complete with single pole 240V
    MCBs of interrupting capacity according to BS EN 60898. The number and size of the
    ov

    outgoing circuits shall be as per the feeder pillar schedules. Terminations shall be capable of
    accommodating sub circuit cable of size 25mm2. There shall be at least 25% spare outgoing
    o

    circuit capacity.
    it
    et

    6 MCBs and protective devices shall be rated to withstand a minimum short-circuit current of
    9kA.
    m

    7 Neutral terminal bar shall be provided separately. Neutral conductors shall be insulated from
    earth to allow use on TN-S systems. The neutral connections shall have separate
    connections for each outgoing cable. Where a neutral busbar is provided it shall be mounted
    in parallel with the phase busbars and arranged so that each neutral connection is physically
    identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of
    the feeder pillar and shall be of sufficient length to accommodate a connection for each
    circuit including 25% spare capacity. The neutral busbar shall be coloured black and the
    earth busbar coloured green and yellow.

    8 Busbars shall be of full rating having taken into account any holes, they shall be constructed
    from high conductivity copper and mounted on insulators and mounted at the rear of the
    feeder pillar. Busbars shall be insulated with non-hydroscopic, non-tracking insulation. All live
    parts shall be screened.
    QCS 2014 Section 06: Roadworks Page 45
    Part 15: Road Lighting

    9 Insulated dividing barriers shall be provided between both phase contact assemblies and
    between phase and neutral.

    10 Each feeder pillar shall accommodate at least 1No. brass cable gland with locknut, earth tag
    and PVC shroud for the incoming supply cable together with individual brass cable glands
    25mm CW gland according to BS 6121 complete with lock nuts, earth tags and PVC shrouds
    for all outgoing cables, including an allowance for spare capacity, for stranded copper cables
    up to 25mm 4 core XLPE SWA PVC.

    11 Colour-coded leads shall identify all wiring for phase and neutral cables. Outgoing circuits
    shall be labelled with the circuit reference and circuit breaker rating. Wherever possible all
    internal wiring shall be enclosed in trunking or conduit.

    15.16 ROAD LIGHTING CABLES

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    15.16.1 Underground Cables

    rw
    1 Underground road lighting cable shall be copper stranded 10/16/25mm x 4 core XLPE SWA
    PVC cable of stranded copper conductor 600/1000 VAC.

    2
    ta
    Cables shall be low tension 600/1000 volt multi core stranded copper conductors, insulated
    qa
    with XLPE compound, core laid-up, extruded PVC tape bedded, steel wire armoured and
    PVC sheathed overall underground cables to BS 5467: 1977.
    as

    3 The cable shall be capable of withstanding vigorous climatic conditions of ambient


    temperature up to 50C (the temperature can be accompanied by a relative humidity of up to
    se

    100% at 30C).
    er

    4 It should also be noted that cables can be buried in sand and laid partly in ducts at a depth of
    up to 600mm in footpaths and 750mm in roadways. The ground temperatures can vary from
    ov

    35-40C in summer to 8-12C in winter. Cable drums may be stored in the open for up to 1
    year and will be exposed to direct sunlight. Accordingly, cables shall be designed to withstand
    such conditions without deterioration of the electrical or mechanical properties.
    it o

    5 Cables shall have the following construction details:


    et

    (a) Conductors: High conductivity stranded copper - shaped conductors shall


    m

    comply with BS 6360: 1981 with XLPE insulation.


    (b) Bedding: Bedding shall be an extruded layer of XLPE compound.
    (c) Colour of Cores: Red, Yellow, Blue and Black.
    (d) Armouring: Single layer of galvanized steel wire.
    (e) Finish (over sheath): Extruded black PVC over sheath which conforms to BS 6346:
    1987 for thickness and to BS 6746: 1987 for properties. The
    external surface shall be embossed with the voltage
    designation, cable size and manufacturers name
    15.16.2 Packing of Cables

    1 Underground cables shall be packed in sealed wooden cable drums each of 500 metres
    length with a plate stating the following details:

    (a) Manufacturer's name and country of origin


    QCS 2014 Section 06: Roadworks Page 46
    Part 15: Road Lighting

    (b) Cable type and size


    (c) Length of cable per drum

    15.16.3 Insulated PVC Sheathed Circular High Temperature (85C)

    1 Flexible cable should be of conductors of high conductivity copper stranded wires, 2.5 sq.
    mm, insulated with high temperature PVC compound, three cores, green or yellow, blue and
    brown, twisted together, filled and sheathed with high temperature PVC compound,
    300/500V.A.C. according to BS 6141, Table 15 or equivalent norm.

    15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES

    15.17.1 General

    .
    1 Marker tape shall be installed wherever cables are to be directly buried in the ground to warn

    l
    .l.
    of the presence of power cables.

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    15.17.2 Material & Quality

    1
    ta
    The marker tape shall be of low density polyethylene, of thickness at least 100 micron. Its
    width shall be 40cm and be yellow in colour, with black marking indicating the presence of
    qa
    road lighting cable in both English and Arabic. Its location in respect of the cable position is
    identified within the Contract documentation.
    as

    2 The material shall be colour fast, and resistant to chemical action in typical ground conditions
    experienced in Qatar. These may vary from extremely wet to extremely dry, and with very
    se

    high salinity. The ground temperature may vary from 0 to 40C.


    er

    3 The material shall be mechanically durable. The manufacturer shall demonstrate the
    samples complying with this specification have been tested for compliance with BS 2782,
    ov

    Part 3, Method 326A to 326C or an equivalent standard.


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    15.18 MARKER POSTS


    it
    et

    15.18.1 General
    m

    1 Where instructed by the Engineer, the Contractor shall install marker posts and slabs. These
    shall be of reinforced concrete, steel or heavy duty plastic of an approved type suitable for
    use in Qatar. Unless instructed otherwise pre-cast reinforced concrete or equally approved
    marker posts or slabs shall be installed at intervals of not more than 50m along all
    underground cable routes, joint pits (if any), at all changes of direction and at both ends of
    road crossings.

    15.19 EARTHING

    15.19.1 General

    1 The integrity of the earthing system within the road lighting network shall be maintained.

    2 Each item of equipment shall be individually effectively earthed within each lighting assembly
    and feeder pillar by means of a dedicated earth to a central earthing point. This shall be
    regardless of any other terminals available. All connections shall use crimped terminations.
    QCS 2014 Section 06: Roadworks Page 47
    Part 15: Road Lighting
    2 2
    3 For circuit conductors of 16mm and 25mm a circuit protective conductor of cross-section
    2
    not less than 16mm shall be incorporated.

    4 All removable metal doors or metal frames shall be earth bonded.

    5 Within the feeder pillar the central earthing point shall be connected to the incoming earth
    provided by QGEWC.

    6 At each feeder pillar location an earth rod shall be installed complete with an approved earth
    pit and cover plate. It shall have a resistance to true earth of not more than 10 ohms. The
    size of the earth rod shall be 16mm by 2.5m in length. It shall be driven to a depth that
    penetrates the summer water table by at least 1m. It shall be connected to the central
    earthing point of the feeder pillar via a bare stranded copper conductor of cross-sectional
    2
    area 70mm .

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    7 At the end of each lighting sub circuit an additional earth electrode as detailed above shall be

    .l.
    connected to the central earthing point within the last lighting column base compartment. The

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    connection between the earth electrode and the column central earth terminal shall be via a
    2
    bare stranded copper conductor of cross-section 16mm .

    8
    ta
    Routing of the earth cable to the ground conductor within the last column of each feeder pillar
    outgoing subcircuit shall be via a 100mm. PVC duct within the column foundation.
    qa
    15.20 INSTALLATION
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    15.20.1 General Requirements


    se

    1 The Contractor is responsible for all liaisons, through the Engineer, with the departments
    er

    concerned within the PWA, in respect of programming the installation and commissioning of
    the complete road lighting system. He shall also ensure through the Engineer that the
    ov

    relevant departments within the PWA are at all times kept informed of the current progress of
    the work. Throughout the road lighting installation works the engineering representative from
    the relevant departments within the PWA, must be invited to carry out periodic inspections of
    o

    the works. The Contractor shall ensure that his approved subcontractor programmes works
    it

    are in the designated sequence in accordance with the approved programme. On completion
    et

    of each phase of the works progress to the next phase will be subject to the approval of the
    m

    Engineers Representative and/or the relevant departments within the PWA.

    2 A qualified person having a thorough experience in road lighting and associated equipment
    shall supervise the execution of all electrical work.

    3 Only workmen who have had experience in the erection of road lighting shall be employed on
    the work of erection.

    4 Before carrying out any electrical works to existing services, authorisation must be obtained
    in writing from all relevant authorities.

    5 The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in
    the ILE Code of Practice for Electrical Safety.

    6 Where an existing installation has been extended the relevant parts of the existing system
    and equipment earthing shall be inspected and tested for compliance with the IEE Wiring
    Regulations.
    QCS 2014 Section 06: Roadworks Page 48
    Part 15: Road Lighting

    7 A completion certificate as detailed in the IEE Wiring Regulations shall be issued following
    the inspection and testing of the installation and any corrective action found necessary.

    15.20.2 Temporary Lighting

    1 Where the existing installation is to be disconnected during the Contract Period, temporary
    lighting shall be provided. Any temporary lighting proposals must have the approval of the
    PWA prior to installation.

    2 At no time shall design road lighting standards be lower than those existing prior to the start
    of the Contract.

    3 The Engineer must approve any form of temporary lighting and associated lighting levels.

    4 Temporary lighting shall not be removed or disconnected until the permanent installation has

    l .
    been inspected and approved by the Engineer and has been energised.

    .l.
    rw
    15.20.3 Removal of Existing Columns

    1 Prior to any work being undertaken the Contractor shall obtain from the relevant departments

    ta
    within the PWA a copy of the latest revised record drawing of the existing lighting network
    within the contract limits. The Contractor is to identify from these records those columns
    qa
    affected by the Contract and require removal or relocating. A copy of any record obtained
    shall be forwarded to the Engineer for his use.
    as

    2 Existing columns shall be removed under supervision of the Engineers Representative in


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    consultation with the relevant department within the PWA. Existing cables shall be
    disconnected, made safe and protected to the satisfaction of the Engineer in consultation
    with the relevant departments within the PWA prior to removal of the columns.
    er
    ov

    3 No existing road lighting shall be switched off, dismantled or removed without the prior
    approval of the Engineer and the relevant departments within the PWA. Where the existing
    road lighting has been removed the Contractor, to ensure safe vehicular and pedestrian
    o

    movement within the designated area, shall provide necessary temporary lighting complete at
    it

    his cost. Existing signs shall also be relocated at the Contractors cost to ensure compliance
    et

    with the current traffic regulations.


    m

    4 All lamps, luminaries and fittings shall be removed before excavating around the column prior
    to its removal. Tie ropes shall support the columns at all times.

    5 The Contractor shall carefully excavate existing material from around the column base,
    including concrete taking care not to damage any adjacent cables or services. No assembly
    shall be removed until it has been fully excavated.

    6 The columns shall be lifted from the foundation by means of a crane approved by the
    Engineer. The foundation shall be backfilled with suitable approved material and temporarily
    reinstated.

    7 All columns, cables, lamps and luminaries to be removed under the Contract shall be taken
    to store as directed by the Engineer and remain the property of the PWA. Where such items
    are instructed to be taken to the stores of the PWA, proof of delivery should be obtained by
    means of a signed receipt from the relevant departments within the PWA and witnessed by
    the Engineers representative.
    QCS 2014 Section 06: Roadworks Page 49
    Part 15: Road Lighting

    8 Existing road lighting, where it is to be relocated within the Contract, shall be carried out in
    accordance with the relevant sections of the contract specifications, as if new. Prior to re-
    installing all equipment it shall be inspected and any damage reported to the relevant
    departments within the PWA, via the Engineer.

    15.20.4 Detailed Drawing for RCC foundation

    1 The foundation for the 3 metre to 12 metre lighting columns shall be in accordance with the
    details provided within the Contract Documents. The reinforcement detail shall be detailed by
    the Contractor based on the recommendations of the column manufacturer to meet the
    column assembly design criteria detailed in paragraph 15.6.7 of this specification. Contractor
    shall consider the use of augured foundations in areas where soil and lighting utility
    reservation necessitate it, as per the Contract Documents.

    2 The foundation detail for the lighting columns or masts between 16 metres to 30 metres will

    l .
    be as recommended by the column manufacturer for the climatic conditions applicable to the

    .l.
    State of Qatar taking due consideration of the equipment to be supported. Contractor shall

    rw
    consider the use of augured foundations in areas where soil and lighting utility reservation
    necessitate it, as per the Contract Documents.

    3
    ta
    Final configuration of the proposed foundation will be subject to the approval of the Engineer
    qa
    and the PWA.

    15.20.5 Road lighting Column/Lantern Installation


    as

    1 Road lighting columns shall be erected on pre-constructed bases offset from the
    se

    carriageway, as defined in the contract Specification, via anchor bolt arrangement.


    er

    2 Prior to erection of the lighting pole no bracket arm or lighting fixtures shall be mounted on
    the column shaft.
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    3 Only purpose made cranes with nylon slings will be accepted for the purpose of lifting the
    columns onto the anchor bolts. Metal chains are not acceptable.
    it o

    4 The bottom securing nut/washer arrangement or shims shall be used to align the lighting
    et

    column vertical. The location of the base compartment door shall be agreed prior to the
    installing of the column shaft, but unless notified otherwise the door opening shall be located
    m

    such that any operative working within the column shall face the on-coming traffic.

    5 Once installed, the final alignment and verticality of the column shall be checked in two
    directions at 90 degrees to each other by theodolite or other approved method. The final
    verticality is to be approved by the Engineers Representative prior to the column bracket and
    luminaire as specified being installed and commissioned.

    6 The underground cables shall be terminated into the cut-out/isolator assembly mounted
    within the lighting pole base compartment. An additional length of 500mm shall be allowed at
    each incoming cable termination and shall remain underground for future reconnections.

    7 Wiring between the terminal block in the luminaire and the components in the base of the
    column or each unit shall be using high temperature 3 core, green or yellow, blue and brown,
    2.5mm2 copper flexible cables to BS 6141.

    8 All installation requirements described in the ILE Code of Practice Clause 11 shall apply.
    QCS 2014 Section 06: Roadworks Page 50
    Part 15: Road Lighting

    9 A double insulated 6.0mm2 stranded copper earth wire with clamped tag bonded to earth lug
    on column and the column door earth terminal shall be provided.

    10 All cable routes shall be clear of control gear and limited to horizontal and vertical runs.
    Cables entering terminals shall show no bare wire nor shall the insulation be taken into the
    electrical conducting part of the terminal. All cable shall be neatly bunched together and
    securely taped.

    11 Terminal blocks shall be clearly marked and the wiring shall be so arranged that the
    luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without
    any electrical wiring disconnections.

    12 After installation each lighting column shall be identified by a reference number in


    accordance with the requirements of the PWA.

    l .
    15.20.6 Road lighting Feeder Pillar Installation

    .l.
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    1 The road lighting feeder pillar shall be erected on pre-constructed base off set to the
    carriageway, as defined in the Contract specification, via anchor bolt arrangement.

    2
    ta
    Prior to erection no internal equipment shall be installed which could be damaged either in
    transit to site or during the erection phase.
    qa
    3 The bottom securing nut/washer arrangement or shims shall be used to align the feeder pillar
    as

    vertical.

    4 The electrical installation within the feeder pillar shall be undertaken as detailed elsewhere in
    se

    the specification.
    er

    5 All underground cables when terminated shall allow for a minimum length of 500mm to be left
    ov

    underground to allow for future reconnections

    15.20.7 Road lighting Cable Installation


    it o

    1 The installation of all cables shall be in accordance with the requirements of QCS Section 21.
    et

    2 2
    2 Excavation of Road lighting Cable trenches for cable size from 10mm to 35mm x 4 core are
    m

    to be of the following dimension:


    Depth: 600mm
    Width: 500mm
    3 Cable trenches shall be cleared of all stone and sharp projections and shall be drained. All
    cables shall be laid on a bed of 150mm approved fine aggregate sand or quarry scalping.
    Cabling to and between columns will be by means of copper stranded 4core
    XLPE.SWA.PVC cable. (Size as indicated and based on the connected electrical load and
    length of cable from power source) and shall be at the depth of 450mm. A layer of 150mm
    dune sand or quarry scalping is to cover the cable. No joints in Cable shall be permitted.
    QCS 2014 Section 06: Roadworks Page 51
    Part 15: Road Lighting

    4 LV cables laid shall be laid straight between lighting columns with an allowance for 500mm
    spare underground cable adjacent to each column. Cables can be placed in the same trench
    with a lateral spacing between cables of 50mm. In the event of HV cables being placed in the
    same trench then there shall be a separation of at least 300mm. All cables shall have a
    clearance of at least 300mm from all other services including telephone or communication
    cables.

    5 The Contractor shall arrange for inspection of the cable, trenches and cable installations by
    the Engineers Representative, in conjunction with the relevant departments within the PWA
    prior to backfilling.

    6 All cables shall be handled, installed and terminated in accordance with the manufacturers
    recommendations. The manufacturers recommended ambient temperature limitations for
    the handling of cables shall be strictly adhered to.

    l .
    7 All cables, once removed from the cable drum, shall be immediately laid in position. No cable

    .l.
    shall remain laying on the surface for more than is practicably possible.

    rw
    8 Cabling is to be looped into each column and terminated by means of an approved lighting
    column cut out.

    15.20.8 Road Crossing Ducts ta


    qa
    1 Underground ducts shall be provided where cables
    as

    (a) Cross roads or other paved areas with vehicular access.


    se

    (b) Cross unpaved areas regularly used by vehicles.


    (c) Enter buildings.
    er

    (d) Vehicular entrances to properties.


    ov

    (e) Pass through corrosive soils or elsewhere as designated, they shall be drawn into
    underground pipe ducts.
    o

    2 A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run
    it

    immediately after its installation. A 2m surplus shall be left at each end of each run, neatly
    et

    coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct.
    m

    3 Underground pipe ducts shall be heavy gauge unplasticised PVC (high impact resistant PVC,
    3.6mm wall thickness) conduits with tapered sleeve or spigot and socket joints encased in
    concrete as detailed in the Contract drawings and in accordance with the requirements of the
    PWA.

    4 All ducts shall have a nominal internal diameter of 150 mm unless designated otherwise.

    5 The internal diameter of ducts used to provide cable entries into structures shall have a
    space factor less than 25 %, unless otherwise designated.

    6 All dual systems shall be installed so that no undue strain is placed on cables when pulled in.
    Cable manufacturers recommendations shall be followed.

    7 All underground cable ducts shall, so far as possible, be run in straight lines.
    QCS 2014 Section 06: Roadworks Page 52
    Part 15: Road Lighting

    8 Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis
    of the road. They shall be laid at a depth of 800mm backfilled and reinstated in accordance
    with QCS.

    9 Except in the case of short isolated duct runs such as road crossings, underground cable
    duct runs shall terminate in suitable drawpits.

    10 Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded
    with concrete of grade SRC 30 as per the standard detail.

    11 Ducts shall be laid so as to drain naturally towards one or both ends, where adequate
    provision for drainage shall be made. Adequate precautions shall be taken to prevent the
    cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of
    1 in 200 shall be provided for drainage purposes.

    l .
    12 Any work carried out requiring the use of split ducts shall be carried out in such a manner as

    .l.
    to preserve the withdrawability of the cables concerned.

    rw
    13 Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is
    liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be

    ta
    installed on a concrete bed as designated above, but without concrete surround.
    qa
    14 If two or more cables are to be installed in the same duct, the aggregate of their cross-
    sectional areas shall not exceed 30 % of the cross-sectional area of the duct.
    as

    15 All trenches excavated for the laying of cable ducts shall be completely backfilled and
    se

    rammed before cable installation work begins.

    16 Immediately following the installation of any duct run, the interior of the duct shall be
    er

    thoroughly cleaned by twice drawing through the ducts a mandrel, once in each direction.
    ov

    Following this, the ends of each run shall be sealed with a suitable hardwood or plastic
    sealing plug which shall be left in position until cable laying is about to begin.
    o

    17 The polished hardwood mandrel shall be 300mm long having spherical ends and a diameter
    it

    6mm less than the nominal duct diameter.


    et

    15.20.9 Backfilling and Re-instatement


    m

    1 All trenches and pole pit/foundations shall be backfilled, compacted and re-instated in
    accordance with the QCS requirements.

    15.20.10 Road lighting Cable Terminations and Testing

    1 Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where
    applicable, and shall be of a design appropriate to the type of cable being terminated.

    2 Glands for cables with metallic inner sheaths shall incorporate a bonding connection.

    3 Except where it is impracticable to do so, the cable cores shall be taken through the
    terminating box directly to the terminals of the equipment, without crosses, and shall be
    made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped
    socket.
    QCS 2014 Section 06: Roadworks Page 53
    Part 15: Road Lighting

    4 Terminations for armoured cable shall incorporate a method of rating off the armour which
    ensures a permanent earth bond between the cables terminated to the satisfaction of the
    Engineer. The cable armour shall be bonded to the earth terminal block in each column.

    5 All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in
    the appropriate colours, to indicate the disposition of the phase and neutral conductors within
    them.

    6 Compression glands installed externally shall be classified IP66 and be provided with close-
    fitting PVC shrouds.

    15.20.11 Electrical Power Supply

    1 Upon the completion of the associated work, arrangements will be made via the Engineer to
    provide the electrical power to each road lighting feeder pillar based on a 415V 50Hz supply.

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    Once available, and after inspection, the lighting system shall be tested prior to connection.

    .l.
    The Engineer shall arrange for full consultation with the relevant departments within the PWA

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    during this phase of the lighting works.

    15.21 TESTING AND COMMISSIONING ON SITE


    ta
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    15.21.1 General

    1 In addition to the requirements of the Contract Specific Specification all testing and
    as

    commissioning shall be carried out according to the requirements of the relevant BS , CP,
    IEE regulations, or other standards and regulations as may be stated or implied in this
    se

    Specification.
    er

    2 Each completed system with the installation shall be tested as a whole under operating
    conditions to ensure that each component functions correctly in conjunction with the rest of
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    the installation.

    3 The Contractor shall afford access at all times to the relevant departments within the PWA to
    o

    enable them to inspect work during and after erection and to be present at all tests.
    it
    et

    15.21.2 Electrical Tests


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    1 As soon as is practicable after the completion of installation the tests described below,
    together with such other tests and measurements to prove compliance with the contract
    requirements shall be made.

    2 An insulation tester shall be used to measure the insulation resistance between each
    conductor and the remaining conductors and between each conductor and the metallic
    sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V.

    3 The above tests shall be carried out both before and after any pressure tests and the
    insulation resistance shall not be less than the figures in the appropriate BS.

    4 A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix
    88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable.

    5 Proposals for the appropriate test in respect of other types of cable shall be submitted for
    approval.
    QCS 2014 Section 06: Roadworks Page 54
    Part 15: Road Lighting

    6 An earth continuity test shall be carried out to verify that the cable armouring and metal
    sheath, if any, have been properly bonded to earth.

    7 Phase rotation and phase correspondence shall be tested to prove that the cables have been
    correctly connected.

    8 Where a new cable has been jointed to an existing cable with the express permission of the
    Engineer, the voltage test designated above may be carried out at a reduced voltage if the
    existing cable has been in service for more than five years. In such a case the test voltage
    shall be determined by applying a factor K to the value given in the appropriate British
    Standard as referred to above.

    9 The Contractor shall afford access at all times to the representatives of QGEWC and the
    relevant departments within the PWA to enable them to inspect work during and after
    erection and to be present at all tests.

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    .l.
    10 Upon completion of laying and terminating underground cable runs, the Contractor, in the

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    presence of the Engineer or his duly authorised representative, shall carry out pressure tests
    in accordance with relevant British Standards. The Contractor shall provide all apparatus and
    labour required for such tests and within a reasonable time thereafter shall present the
    Engineer with certificates of the tests.
    ta
    qa
    15.21.3 Photometric Performance Testing
    as

    1 A certificate of Initial Lighting Performance of Installation shall be issued when tests have
    been passed as follows:
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    (a) The initial photometric tests shall be made after the installation has been in lighting
    operation for between l00 and 150 hours
    er

    (b) The location of test positions shall be distributed along the length of the installation and
    ov

    shall be as directed by the Engineer. All service tests throughout the testing period
    shall be made at these positions.
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    2 Readings shall be taken with a portable calibrated luminance meter holding a current valid
    it

    calibration certificate. The measurements in accordance with the procedures laid down by the
    et

    CIE and shall be taken by a qualified lighting engineer who shall confirm that the lighting
    performance data as identified in the contract specification has been satisfactorily obtained.
    m

    3 Measurement of the supply voltage at adjacent lighting columns and posts shall be taken at
    the time of each test and the illumination measurement shall be adjusted for any variation
    from the supply voltage value declared in the contract specification. Allowance shall be made
    for the use of control gear taps if necessary immediately before the initial tests are made.
    The lamps and all components of the luminaire that may affect the optical performance shall
    be cleaned and correctly adjusted.

    4 The Engineer shall witness all photometric testing, unless otherwise notified in writing. A
    minimum of 7-days notice shall be given to the Engineer before testing begins. After testing
    the certificates shall be submitted to the Engineer for approval. Representatives from the
    relevant departments within the PWA shall be invited to witness the lighting performance
    testing.
    QCS 2014 Section 06: Roadworks Page 55
    Part 15: Road Lighting

    15.22 RECORD DRAWINGS

    15.22.1 General

    1 Within thirty days from the date of completion of the whole or any section of the lighting works
    the Contractor shall provide fully detailed "as built" drawings and schedules in respect of all
    sections of work completed together with all relevant operating and maintenance instructions.
    The drawings shall: -

    (a) Fully indicate with accurate dimensions the sizes, types and position of equipment,
    cables, ducts, joints, feeder pillars etc., with particular regard for the need to accurately
    locate buried cables after completion.
    (b) Show the circuit arrangements for the relevant section of the road lighting installation.
    (c) Show full details, ratings and function of each item of equipment.

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    .l.
    (d) Include any other relevant information to ensure the safe and satisfactory operation of
    the particular section of the road lighting works.

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    2 The Contractor shall submit, within the time stated above, two copies of the Record Drawings
    for the approval of the Engineer. Upon and after receipt of such approval the Contractor shall

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    provide records in both digitised and hard copy format of reproducible transparent negative
    qa
    drawings, and two sets of prints on paper to the Engineer for his retention.

    3 In addition to the foregoing, the Contractor shall provide in each feeder pillar and distribution
    as

    unit a good quality print on paper showing the road lighting distribution line diagram of that
    particular section. These prints shall be mounted on the inside of the door of each feeder
    se

    pillar and distribution unit and shall be covered in clear plastic to prevent undue deterioration.
    er

    4 In order to achieve accurate Record Drawings all relevant information relating to the lighting
    works shall be entered on to the stated drawings and kept for immediate use once the work
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    has been carried out. The marked prints shall be available for inspection at the Contractor's
    site office at any reasonable time during the progress of the lighting works.
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    END OF PART
    et
    m
    QCS 2014 Section 06: Road Works Page 1
    Part 16: Traffic Signals

    16 TRAFIC SIGNALS ......................................................................................... 2


    16.1 GENERAL ...................................................................................................... 2
    16.1.1 Summary 2
    16.1.2 References 2
    16.1.3 Submittals 2
    16.1.4 Quality Assurance 3
    16.1.5 Delivery, Storage and Handling 3
    16.1.6 General Project/Site Conditions 4
    16.1.7 Warranties 4
    16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT .............................................. 4
    16.2.1 General 4
    16.2.2 Identification of Equipment 5

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    16.2.3 Traffic Signal Posts 5

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    16.2.4 Traffic Signal Gantries 5

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    16.2.5 Three-Aspect Traffic Signal Heads 6
    16.2.6 Two-Aspect Pedestrian Signal Heads 7
    16.2.7 Traffic Signal Controllers
    16.2.8 Pedestrian Operated Push-Buttons ta 10
    8
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    16.2.9 Flexible Traffic Signal Cable 10
    16.2.10 Armoured Traffic Signal Cable 10
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    16.2.11 Loop Cables 11


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    16.2.12 Loop Feeder Cables 11


    16.2.13 Pulling Chamber Cover 11
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    16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 12


    16.2.15 General Compatibility 12
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    16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT ................................. 12


    16.3.1 General 12
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    16.3.2 Poles, Gantries and Signal Heads 12


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    16.3.3 Installation of Traffic Signal Controller 13


    16.3.4 Cabling 13
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    16.3.5 Circuit Protection and Earthing Requirements 14


    16.3.6 Permanent Electrical Power Supply 15
    16.3.7 Inductive Loops for Vehicle Detection 16
    16.4 TESTING AND COMMISSIONING .............................................................. 20
    16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL
    EQUIPMENT ............................................................................................... 21
    16.5.1 General 21
    16.5.2 Operational Maintenance 21
    16.5.3 Emergency Maintenance 23
    16.5.4 Contractors Vehicles 23
    16.5.5 Contractors Equipment 23
    QCS 2014 Section 06: Road Works Page 2
    Part 16: Traffic Signals

    16 TRAFIC SIGNALS
    16.1 GENERAL

    16.1.1 Summary

    1 This Part includes the provision of traffic signal equipment and related street furniture at
    controlled roadway junctions and pedestrian crossings.

    2 Related Sections
    Section 1 General
    Section 5 Concrete
    Section 9 Mechanical and Electrical Equipment

    .
    Section 10 Instrumentation, Control and Automation

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    Section 21 Electrical Works

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    16.1.2 References
    The following standards are referred to on this Part:

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    BS 1361......................Cartridge fuses for a..c circuits in domestic and similar premises
    BS 381C .....................Specifications for colours for identifications
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    BS 5493......................Code of practice for protective coatings of iron and steel structures
    against corrosion.
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    BS 7430......................Code of practice and regulations for earthing


    BS 7671......................Requirements for electrical installations
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    BS 88..........................Cartridge fuses for voltages up to and including 1000 Vac and 150 Vac
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    BS EN 1011................Process of arc welding carbon and carbon manganese steels


    BS EN 12368..............Road traffic signals
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    BS EN 13108..............Fine cold asphalt


    BS EN 60529..............Degrees of protection provided by enclosures
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    BS EN ISO 146 ..........Hot dip galvanised coatings on iron and steel articles
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    AASHTO Standard specification for supports for highway signs, luminaires, traffic signals
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    DIN 40050 ..................Enclosures for electrical equipment


    DIN 6163 Part 5..........Diffusion lenses for traffic signals

    QGEWC (E) Regulations for Electrical Installations


    QGEWC (E) Regulations for Protective Multiple Earthing

    16.1.3 Submittals

    1 The Contractor shall submit to the engineer for approval shop drawings for each type of
    signal pole, gantry and mounting frame for signal heads to be provided under the Contract
    along with structural calculations. The drawings shall show materials specification and
    finishes for each component proposed for use. All weld types and sizes shall be identified on
    the shop drawings.
    QCS 2014 Section 06: Road Works Page 3
    Part 16: Traffic Signals

    2 The Contractor shall submit to the engineer for approval design calculations for the proposed
    signal poles and gantries. The design calculations shall be carried out in accordance with the
    AASHTO Standard specification for supports for highway signs, luminaires, and traffic signals

    3 The Contractor shall propose a design for the foundations for each type of signal pole and
    gantry and shall submit design calculations and drawings to the Engineer for approval.

    4 The Contractor shall submit to the engineer for approval a schematic wiring diagram for all
    the installations. The Contractor shall also submit a wiring layout drawing for the cable loops
    and the cross-sectional details of the cut in the road surface.

    16.1.4 Quality Assurance

    1 Contractors for the works shall be experienced specialists in the field of traffic control
    systems with a minimum of 5 years experience of the installation, commissioning and testing

    l .
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    of such systems in a similar environment.

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    2 The Contractor shall submit a technical submission for the proposed subcontractor giving
    details of previous installations date installed, client, technical data for proposed materials,
    and experience record of proposed installation staff, supervisors and management.
    ta
    qa
    3 Installation of traffic signal equipment shall only be conducted by approved specialist
    subcontractors. The specialist subcontractors shall be approved by the PWA.
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    4 The performance and design requirements work shall be in compliance with QGEWC
    Regulations for Electrical Installations.
    se

    5 All equipment supplied shall, in general, conform to the same style, colours and functions as
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    that already in place in Qatar. The supplier may be required to provide, at his own expense,
    samples of his proposed equipment.
    ov

    6 All equipment and installation shall be in accordance with the latest edition of the Qatar
    Traffic Manual. For all signalled intersections and pedestrian signal control crossings the
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    timing sequence of signals displayed to drivers during phases shall be as per information
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    given by the PWA and/or Traffic Police.


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    16.1.5 Delivery, Storage and Handling

    1 Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
    acceptance test in his workshop. The programmed and internally complete controller shall
    be connected to a labelled light board capable of simulating all traffic signal aspects
    controlled by that particular controller. The Contractor shall ensure that all equipment and
    devices are available to show that the controller fully complies with operational requirements.
    The factory acceptance test shall consist of the following checks:

    (a) visual check of internal wiring and controller assembly


    (b) operation of green conflict monitor
    (c) intergreen times
    (d) group times
    (e) detector logic (where applicable)
    (f) stage to stage change logic
    (g) lamp switching.
    QCS 2014 Section 06: Road Works Page 4
    Part 16: Traffic Signals

    2 The Contractor shall be responsible for the delivery of all items to the project site or to any
    site as required by the Engineer.

    16.1.6 General Project/Site Conditions

    1 All equipment and associated components shall be designed and suitably rated to ensure
    proper maintenance, continuous trouble free service under the prevailing climatic conditions.
    All equipment and installation shall operate satisfactorily in a temperature range of 0 C to
    +55 C and under humidity conditions ranging from 10 % to 100 %.

    16.1.7 Warranties

    1 All warranties and guarantees for traffic signal equipment shall commence from the day of
    commissioning. The warranty period shall be that as designated by the manufacturer but

    .
    shall in any case not be less than 400 days

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    16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT

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    16.2.1 General

    1 ta
    It shall be the Contractors responsibility to ensure that all equipment supplied is approved.
    qa
    The Engineer will advise on approved suppliers.

    It shall be the Contractors responsibility to honour the designated warranty periods..


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    3 The Contractor, shall make himself aware of any lead times required for delivery of
    se

    equipment and programme his works accordingly. It shall be the Contractors responsibility to
    ensure that equipment is available as needed, any delays to works resulting from the
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    unavailability of equipment shall be deemed to be the responsibility of the Contractor.


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    4 The Contractor shall be responsible for the correct delivery, storage and handling and
    storage of all equipment up to the time it is commissioned.
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    5 All equipment shall comprise of units of a type that have been used successfully in other
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    installations in a similar environment, from a minimum period of six months and shall be
    subject to approval of the engineer. Particular attention shall be given in the selection and
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    design of equipment and components to the exclusion of water, moisture and dust.

    6 Components and materials that may perish and deteriorate in the climatic conditions of Qatar
    shall be avoided. All equipment shall be so constructed as similar units that shall be readily
    available and completely interchangeable both mechanically and electrically.

    7 The location layout of each installation and the number of phases and stages for each traffic
    controller shall be as designated Controllers shall provide the signal sequences and phasing
    designated for each installation.

    8 The structural design and traffic signal posts and traffic signal gantries shall be in accordance
    with provisions of AASHTO standard specification, Supports for Highway Signs, Luminaires,
    Traffic Signals, or an approved alternative.
    QCS 2014 Section 06: Road Works Page 5
    Part 16: Traffic Signals

    16.2.2 Identification of Equipment

    1 The Contractor shall mark or clearly label all modules, units and main parts of a system with
    a functional code or title, type number, serial number as approved by the Engineer.

    2 Marking shall maintain legibility throughout the life of the equipment under the prevailing
    environmental conditions.

    3 The labelling system shall comply with the GIS system (as defined in the data dictionary)
    used by the Government of Qatar and the PWA.

    16.2.3 Traffic Signal Posts

    1 Traffic signal poles shall be of the tubular steel type with a flanged base, having an internal
    electrical termination point accessible through a lockable inspection window. The supply of a

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    traffic signal pole shall include; holding down bolts, nuts, washers and shims required for

    .l.
    erection; pole; terminal block; locking cover for inspection window complete with three sets of

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    keys; all grommets; glands and cable anchor points.

    2 Traffic signal poles shall have dimensions conforming to those given in the contract
    Drawings.
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    3 The traffic signal poles shall be of mild steel construction. Corrosion protection shall be
    through the use of a hot dipped galvanised coating conforming to the requirements of British
    as

    Standard BS 5493 and BS EN ISO 1461, depth of galvanised coating shall be 85 microns.
    All welded connections shall conform to British Standard BS EN 1011.
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    4 The termination point shall consist of a terminal block positioned internally within the traffic
    signal pole. The terminal block shall be fully accessible through a lockable inspection
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    window. The terminal block shall be securely fixed to the traffic signal pole.
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    5 The terminal block shall be electrically isolated from the traffic signal pole and shall have a
    minimum capacity of 2 x 20 No. connectors. Each connector shall have a minimum rated
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    capacity of 100 watts at 240 volts.


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    6 The connectors on the terminal block shall be in compliance with the requirements of the
    QGEWC.
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    7 The traffic signal pole shall have the facility to secure incoming cables at a point prior to them
    being connected to the terminal block

    8 The traffic signal pole shall be fitted with an electrical earthing stud, such that at least four
    earth connections can be made to it.

    16.2.4 Traffic Signal Gantries

    1 Traffic signal gantries shall be of the tubular steel type with a flanged base, having an internal
    electrical termination point accessible through a lockable inspection window. The supply of a
    traffic signal gantry shall include: holding down bolts, nuts, washers and shims required for
    erection; pole caps; terminal block; locking cover for inspection window complete with three
    set of keys; all grommets, glands and cable anchor points. Traffic signal gantry shall be
    styled in accordance with Contract Drawings.
    QCS 2014 Section 06: Road Works Page 6
    Part 16: Traffic Signals

    2 The traffic signal gantries shall have minimum dimension conforming to those given in the
    Drawings. The design of the gantries is open to submission by the supplier.

    3 The supplier shall provide full details of the materials used and the method of construction
    employed when quoting for this item, this shall include workshop fabrication drawings,
    material specifications and calculations pertaining to the structural design of the gantry. The
    gantry shall be capable of supporting three aspect traffic signal heads, each having a total
    weight of 25 kg, inclusive of mountings. The number and position of heads are to be as
    designated.

    4 With regard to termination points, cable anchor points and earthing points, these shall be as
    specified in Section 6 Part12 of this Specification

    5 The supplier shall furnish full details of the foundation requirements for his proposed gantry,
    this shall include details of dimensions, reinforcement, quality of concrete and fixings.

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    Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanized to BS EN ISO 1461.

    .l.
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    6 The gantry and foundation design shall be such that the gantry is completely detachable from
    the foundation, should this be required.

    7
    ta
    The gantry shall have a system such that it can be adjusted subsequent to installation, to
    allow for leveling and turning.
    qa
    8 The supplier shall furnish full details of the proposed foundation for his proposed gantry, this
    as

    shall include details of dimensions, reinforcement, quality of concrete and fixings. The gantry
    and foundation design shall be such that the gantry is completely detachable from the
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    foundation, should this be required. Anchor bolts shall be Grade 8.8 and shall be hot-dip
    galvanised to BS EN ISO 1461. The gantry shall have a system such that it can be adjusted
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    subsequent to installation, to allow for levelling and truing.


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    9 The electrical termination point shall consist of a terminal block positioned internally within
    the gantry. The terminal block shall be fully accessible through a lockable inspection window.
    The terminal block shall be securely fixed to the gantry.
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    16.2.5 Three-Aspect Traffic Signal Heads


    et

    1 Three-aspect traffic signal head dimensions shall be as designated. The Contractor shall
    m

    submit drawings of the proposed units.

    2 Signal heads shall comprise of a polycarbonate body containing three traffic signal aspects,
    coloured red, amber and green and shall include:

    (a) lamps
    (b) reflectors
    (c) lenses
    (d) transformers
    (e) visors
    (f) anti-phantom devices (if designated)
    (g) brackets, frames and all fixtures and fittings required for mounting
    (h) backing board.
    QCS 2014 Section 06: Road Works Page 7
    Part 16: Traffic Signals

    3 Signal heads shall be constructed, in as far as is possible, out of high quality polycarbonate
    plastic. Any metal fittings shall be suitably protected against corrosion.

    4 The design and construction of signal heads shall allow for all of the following features:

    (a) hinged lens panels to allow quick access to the lamps


    (b) flexible, detachable visors
    (c) easily adjustable mounting system
    (d) capability of internally fitting optical arrow mask.

    5 The signal heads shall use, for each aspect, a 10 volt halogen lamp of type SIG 64015/1 -
    50W or SIG 64015 - 50W. The lamp holder and connectors shall be compatible with the type
    of lamp used. The lamps shall conform to BS EN 12368. The supply voltage to the signal
    head shall be 240 volts ( 5 %) and shall be converted to the lamp voltage by the use of a

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    standard design transformer (El Type). Each aspect shall have an individual transformer,

    .l.
    these transformers shall be fitted with noise suppression equipment. The transformers will be

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    required to operate in ambient temperatures up to 60 C. The transformers shall have a
    minimum operational life of five years with an effective switch-on ratio of 3300: 4380.

    6
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    Signal heads shall be capable of being mounted on the traffic signal pole or gantry as
    qa
    designated or, in the case of traffic signal gantry, as may be proposed by the Contractor.
    The mounting system used shall be such that no predrilling or permanent attachment of
    brackets to the signal pole or gantry is required. The mounting system shall be such that the
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    signal head shall be capable of being adjusted through an arc of 30 degrees about its vertical
    axis. It shall be possible to mount two three-aspect traffic signal heads side by side on a
    se

    single pole such that the vertical faces being presented to oncoming traffic of each head
    remain in the same plane. It shall be possible to mount the signal heads asymmetrical from
    er

    the centreline of the pole. The signal head shall be rendered splash proof by means of an
    lP54 enclosure. The item description covering signal heads shall include, where necessary,
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    extra mounting brackets to enable the above facilities.


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    7 The optical reflector shall be made of a high grade aluminium, mirror finished. Diffusion
    it

    lenses shall be constructed with an internal cobweb pattern and shall be coloured red, amber
    et

    or green as defined by the colour limits laid down in the DIN Standard DIN 6163 Part 5.
    m

    16.2.6 Two-Aspect Pedestrian Signal Heads

    1 Two-aspect pedestrian signal heads shall have the designated dimensions. The Contractor
    shall submit drawings of the proposed units.

    2 Signal heads shall comprise of a polycarbonate body containing two pedestrian signal
    aspects, coloured red and green and shall include:

    (a) lamps
    (b) reflectors
    (c) lenses
    (d) transformers
    (e) visors
    (f) anti-phantom devices (if designated)
    (g) brackets, frames and all fixtures and fittings required to mount the signal head.
    QCS 2014 Section 06: Road Works Page 8
    Part 16: Traffic Signals

    3 The material, electrical and mounting requirements for the signal head shall be the same as
    the requirements for the three aspect traffic signal head.

    4 The optical requirements for the signal head shall be the same as the requirements for the
    three aspect traffic signal head with the additional requirement that each aspect of each two
    aspect pedestrian signal head be supplied with a 'Walking Man' and 'Stopping Man' optical
    mask.

    16.2.7 Traffic Signal Controllers

    1 Traffic signal controllers shall be microprocessor based and capable of meeting all the
    designated requirements. The Contractor shall submit drawings of the proposed units.

    2 Supply shall include:

    .
    (a) basic control hardware including relays housings and cabinets

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    (b) all required additional modules and circuits

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    (c) all internal wiring
    (d) all detector modules and control circuits
    (e) ta
    plates, fixings and fastenings, glands, seals and clips.
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    3 The controller shall be provided with the following operational modes:
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    (a) computer control


    (b) standby co-ordinated
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    (c) local mode with multi-plan operation


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    (d) flashing
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    (e) manual mode


    (f) signal on/off mode.
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    4 Means will be provided within the controller housing to select and to test each of these
    it

    modes of operation.
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    5 For pedestrian crossings the controller shall be capable of showing a green flashing man
    before the end of each pedestrian phase.

    6 All controllers shall include a dimming feature.

    7 Controllers shall be of a manufacturers type approved by the PWA and/or Traffic Police.

    8 All equipment supplied shall be compatible with the existing traffic signal controllers in use in
    the state of Qatar.

    9 Where the supplier cannot provide evidence of his equipment having been previously
    successfully used with the above traffic signal controllers, he shall be required to
    demonstrate, at his own expense, the compatibility of his equipment.

    10 Traffic signal controllers shall be programmed as designated and as agreed with the
    Engineer. It shall be the Contractors responsibility to provide competent personnel to
    programme the controller.
    QCS 2014 Section 06: Road Works Page 9
    Part 16: Traffic Signals

    11 Each controller shall be supplied with full documentation which shall include :

    (a) wiring diagrams


    (b) timing charts
    (c) intergreen tables
    (d) stage diagrams
    (e) any other relevant information relating to the operation.

    Three copies of the documentation shall be supplied with each controller.


    12 The controller shall be housed in the cabinet of sufficient size to accommodate the controller
    and all other associated equipment and shall provide easy access for maintenance and test
    purposes. The controller and associated equipment shall be arranged within the cabinet so

    .
    that they will not interfere with the entry and exit cables. The cabinet to house signal

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    .l.
    controllers shall be constructed of aluminium sheet of thickness 3 mm in accordance with BS

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    EN 12368 or with non-metallic materials where the properties for abrasion resistance,
    exposure to the elements are equal or better than aluminium cabinet. Cabinets shall be
    painted to a colour and specification agreed by the Engineer. The cabinet shall be

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    weatherproof, rain proof and dust proof and be able to maintain proper operation of
    equipment. The Contractor shall construct a suitable foundation for the cabinet. and it shall
    qa
    allow for the entry and exit of all cables. The cabinet shall be secured to the foundation by
    anchor bolts.
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    13 The traffic signal controller shall be micro-processor based and capable of meeting all the
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    requirements of the operational Specification and any further requirements as specified by


    the Engineer. The supply of a traffic signal controller shall include for: the basic control
    hardware including relays housings and cabinets, all additional modules and circuits required
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    to meet the operational Specification, all internal wiring, all detector modules and control
    ov

    circuits, plates fixings and fastenings glands, seals and clips.

    14 Traffic signal controllers shall be of an approved type and supplied by an approved


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    manufacturer taken from the most recent list prepared by the Public Works Authority.
    it
    et

    15 Traffic signal controllers shall be programmed according to the operational Specification and
    as agreed with the Engineer. It shall be the Contractors responsibility to provide competent
    m

    personnel to programme the controller.

    16 The traffic signal controller shall also have the following capabilities:

    (a) To give a flashing red pedestrian man before switching to a red man at the end of
    pedestrian cycle.
    (b) The controller shall include a timing feature.
    (c) The controller shall support two power supply inputs coming from two different
    substations. The purpose is to continuously operate the controller in case of power
    failure on one substation by automatically transferring to the other power supply input.
    (d) The controller shall be made to ensure that the dual power supply input is stabilized at
    240 volts.
    (e) The controller can be operated manually.
    QCS 2014 Section 06: Road Works Page 10
    Part 16: Traffic Signals

    (f) The controller shall be capable of providing flashing green before switching to
    yellow/amber at the end of vehicle green phase
    (g) The controller shall be capable of providing continuous flashing yellow/amber in the
    channelized island.

    17 Each traffic signal controller shall be fully documented, this shall include: wiring diagrams,
    timing charts, intergreen tables, stage, diagram and any other relevant information relating to
    the operation. Three (3) No. copies of the documentation shall be supplied with each
    controller.

    16.2.8 Pedestrian Operated Push-Buttons

    1 Pedestrian operated push-buttons shall comply with the requirements and regulations of the
    QGEWC.

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    2 The push-button shall include traffic signs as per the Qatar Traffic Control Manual either as
    an integral part, or be mounted separately on the traffic signal pole or gantry.

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    3 Push-buttons shall comprise of a metal or plastic body containing a push-button switch and
    an illuminated text panel in Arabic and English.

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    4 The unit shall have a light that provides confirmation after a pedestrian has pushed the
    button.
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    5 The dimensions and position of the push-buttons shall be proposed by the supplier and
    approved by the Engineer.
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    6 Push-buttons shall be constructed of metal or high grade plastics.


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    16.2.9 Flexible Traffic Signal Cable


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    1 Flexible traffic signal cable shall comprise of four cored, PVC coated, internal core PVC
    coated, cable. The cable shall be PVC sheathed wiring, catalogue description being NYM-J,
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    page 2/3 or equivalent.


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    et

    2 The cable shall be of a rated voltage and current carrying capacity suitable for the proposed
    cable runs. The Contractor shall submit calculations showing the voltage drop for the cable.
    m

    3 Cable shall be supplied in 500 metre lengths and wound onto a suitable cable drum.

    4 Cable shall have a minimum cross-section area of the conductor in each core of 1.5 mm2
    and the overall diameter of the cable shall be 11 mm. The individual core may be either solid
    or stranded. Each core shall be uniquely identifiable by coloured PVC sheathing.

    16.2.10 Armoured Traffic Signal Cable

    1 Armoured traffic signal cable shall comprise of a multi-cored (number of cores as specified),
    PVC coated, copper wire armoured, internal core PVC coated, cable. Catalogue description
    being, PVC-CWA-PVC or equivalent.

    2 Cable shall be supplied in 500 m lengths, wound onto a suitable cable drum.
    QCS 2014 Section 06: Road Works Page 11
    Part 16: Traffic Signals

    3 Cable may be supplied in three sizes, 7 core, 12 core or 19 core. The minimum area of the
    conductor in each core shall be 1.5 mm2. The individual cores may be either solid or
    stranded. Each individual core shall be uniquely identifiably by either having a uniquely
    coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.

    16.2.11 Loop Cables

    1 Loop cables shall consist of a heat resistant coated core cable. Loop feeder cables shall
    comprise of a communication type cable, PVC coated having six pair of individually coated
    cores. The Loop shall be manufactured by Never Fail Loop Systems, USA (local
    representative Traffic Tech (Gulf), P.O. Box 9377, Telephone Number 4621814) or similar
    approved.

    2 Loops shall be constructed from polypropylene conduit with 9.5mm inside diameter and

    .
    16mm outside diameter. Conduit shall be filled with hot rubberised asphalt which allows the

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    loop to remain flexible once cooled to prevent incursion of moisture and set the turns of wire
    firmly in place. Loops shall have 127mm expansion/contraction joints at intervals along the

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    loop to allow for movement. Each expansion/contraction joint shall have a 229mm long
    schedule 80 polypropylene cover slide to be placed over the joint.

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    Lead-in wires shall be encased in a non-conductive 2250 psi flex hose constructed with a
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    seamless extruded polyester fiber braid reinforcement and a non-conductive, seamless
    extruded urethane non-perforated jacket. Fill lead-in hose completely with hot rubberised
    asphalt. Twist wires in all lead-ins with a minimum of three turns per 305 mm for the entire
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    length of the lead-in. Attach lead-ins to loop heads with a sch. 80 CVPC tee.
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    4 Loop cable shall have one individual core, the conductor of which shall have a cross-
    sectional area of 1.5 mm2. The loop cable such that the coating is able to withstand direct
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    application of temperatures up to 175 C.


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    16.2.12 Loop Feeder Cables


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    1 Loop feeder cable shall have six pairs of individual cores, each of which having a conductor
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    of cross-sectional area of 0.6mm2. Each individual core shall be uniquely identifiable by


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    either, having a uniquely coloured PVC-U sheathing or by its PVC-U sheathing having
    unique, repetitive marking.
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    2 The use of alternative types of cable may be permitted with the express written permission of
    the Engineer.

    3 Each individual core shall be uniquely identifiable by either having a uniquely coloured PVC
    sheathing or by its PVC sheathing having a unique, repetitive marking.

    16.2.13 Pulling Chamber Cover

    1 Pulling chamber covers shall be of ductile iron.

    2 The pulling chamber covers shall have a square opening of the dimensions shown on the
    project drawings.

    3 The pulling chamber covers shall be inscribed with wording to identify the type of service and
    the system reference. The exact wording shall be to the approval of the Engineer.
    QCS 2014 Section 06: Road Works Page 12
    Part 16: Traffic Signals

    16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts

    1 Unplasticised Polyvinyl Chloride shall be supplied in two different sizes, 2 inches diameter or
    4 inches diameter (50mm or 100mm). The colour shall be dark gray. The PVC-U shall be
    either encased burial type or direct burial type. Catalogue description being, PVC-U
    Electrical Conduit & Tubing and Utility Duct, NEMA TC-6 or NEMA TC-8 or equivalent.

    2 Unplasticised polyvinyl chloride ducts shall be supplied in 6 metre lengths with solvent weld
    socket on one end. The minimum wall thickness shall be 1.52 mm for 2 inches diameter and
    2.08 mm for 4 inches diameter.

    16.2.15 General Compatibility

    1 All equipment supplied shall, in general, conform to the same style, colours and functions as

    .
    that already in place in Qatar. The supplier may be required to provide at his own expense,

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    samples of his proposed equipment. These samples shall become the property of the PWA,
    whether or not an order is placed.

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    2 All equipment supplied shall be compatible with the approved traffic signal controllers and

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    supplied by an approved manufacturer according to the most recent approved list of the
    PWA.
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    3 Where the supplier cannot provide evidence of his equipment have been previously used
    successfully with the above mentioned traffic signal controller, he shall be required to
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    demonstrate, at his own expense, the compatibility of his equipment.


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    16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT


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    16.3.1 General
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    1 It shall be the Contractors responsibility to ensure that all traffic signal installation work is
    conducted by skilled, competent personnel.
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    2 The Engineers approval of any subcontractor or individual personnel in no way relieves the
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    Contractor of his responsibility to ensure that traffic signal equipment is correctly installed.
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    3 The Engineer shall reserve the right to inspect and approve all installation practices.

    4 Installation of traffic signal equipment shall only be conducted by approved companies taken
    from the most recent list prepared by the PWA.

    16.3.2 Poles, Gantries and Signal Heads

    1 Signal posts and gantries shall be installed onto their prepared foundations, using two
    levelling nuts or an appropriate fixing method approved by the Engineer. The pole or gantry
    shall be plumbed square, irrespective of the orientation of surrounding features.

    2 The Contractor shall take every precaution to prevent damage to the pole or gantry's
    protective coating, during installation. Where the protection is damaged or breached the
    Contractor shall take immediate action to make repairs.
    QCS 2014 Section 06: Road Works Page 13
    Part 16: Traffic Signals

    3 Where designated, posts and gantries where necessary shall be painted with an approved
    paint, colour grey (BS 381C) before installation of signal heads and push-buttons..

    4 Signal heads and push-buttons shall be installed as shown on the contract drawings. Final
    positioning and fixing shall not be undertaken without the Engineers approval.

    5 Signal heads, once fixed, shall be covered with an opaque protective material such that it is
    clear to motorists that the signals are not in operation.

    16.3.3 Installation of Traffic Signal Controller

    1 The Contractor shall install the controller housing in the position defined by the Engineer. The
    Contractor shall ensure that the housing is positioned so that when the access doors are
    opened to their fullest extent they will not obstruct the sidewalk or cause a danger in any way
    to members of the public. The housing shall not be positioned adjacent to the kerb as to

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    render it liable to damage by vehicles or so that the safety of persons working on the

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    controller is not endangered.

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    2 The Contractor shall organise the connection of the electricity supply to the controller housing
    and any other peripheral equipment requiring an electricity supply by direct liaison with the

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    QGEWC (E) Consumer Section. The Contractor shall ensure that the power supply is
    contained within its own separate duct, up to the point at which it enters the controller
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    housing. The electrical supply shall at no point share the same ducts or chambers as the
    traffic signal cabling. The Contractor, where necessary, shall be responsible for providing any
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    housings required for QGEWC apparatus. Where a separate housing is required it shall be
    positioned directly adjacent to the controller housing.
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    3 The Contractor shall endeavour to complete as much of the internal wiring of the controller as
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    possible inside his workshop, such that on-site work within the controller housing are kept to
    a minimum. All external cables terminating within the controller shall be clearly labelled as to
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    their function, destination and nominal voltage. These cables shall, on entering the controller
    housing, be clamped and supported such that any stress or strain on the cables themselves
    shall not be transmitted to the controllers internal components. Spare or redundant cables
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    entering the controller housing are to be terminated in such a fashion that they do not
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    interfere in any way with access to the controllers internal components. The conductors of
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    these cables are to be electrically isolated and sealed against the ingress of moisture.
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    4 It shall be the Contractors responsibility to provide all competent personnel and specialist
    equipment to enable the controller to be programmed.

    16.3.4 Cabling

    1 The Contractor shall install all cables in the ducts as designated. He shall take all reasonable
    care to ensure that no undue stress or strain is placed on the cable during installation and
    shall adhere to the cable manufacturers published data with regard to allowable minimum
    radius of curvature. The Contractor shall ensure that duct drawstrings remain in place
    subsequent to cable installation.

    2 A single dedicated cable shall service each individual traffic signal pole. This cable shall be of
    the designated size and shall have a minimum of 10 % spare capacity. On entering the signal
    pole the cable shall be firmly anchored to the pole. At least 3 m of spare cable shall be
    allowed for within the signal pole, over and above that length which is required to reach the
    termination block.
    QCS 2014 Section 06: Road Works Page 14
    Part 16: Traffic Signals

    3 Spare or redundant cores within the cable shall be terminated at the termination block and
    labelled 'Spare'. The core acting as earth protection shall be connected directly to the body
    of the signal pole by means of the poles earthing stud. The cable armouring shall not be
    used as the protective earth conductor.

    4 With the exception of loop cable to loop feeder cable connections, the jointing of cables shall
    not be permitted. Where jointing of the cables is permitted, this shall be undertaken using a
    suitable jointing kit of an approved type which allows the integrity of the protective earth
    conductors to be maintained. Loop cable to loop feeder cable joints shall only be located
    within an access chamber.

    16.3.5 Circuit Protection and Earthing Requirements

    1 The Contractor shall provide protection against dangerous earth-leakage currents by the use
    of fuses or excess-current circuit breakers compliant with the QGEWC (E) Regulations for

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    Electrical Installations. The Contractor shall ensure that all installations shall be such as to
    allow for the operation of the protective devices to operate upon the occurrence of a fault

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    within the time period specified for fixed equipment installations and that all non-current
    carrying metallic parts shall be connected to the earth terminal in such a manner as to ensure

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    that a hazardous voltage cannot exist on exposed conductive metalwork. All cabinets, posts
    and other metal hardware comprised by the traffic signalling equipment shall be bonded via
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    protective conductors to the main earth terminal with an earthing conductor to the main
    terminal by a protective conductor.
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    2 The main earthing terminal or bar shall comply with QGEWC (E) Regulations for Electrical
    installation and shall be connected to the earthing point provided by the QGEWC (E) with a
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    copper earthing conductor in accordance with the Regulations. It shall have a minimum
    cross-sectional area of 6.00 mm2 and shall be green/yellow stripe coded. The earthing
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    conductor is defined as a protected conductor connecting a main earthing terminal or bar of


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    an installation to an earth electrode of other means of earthing. Where a residual current


    circuit breaker is used, the cross sectional area of the earthing conductor shall comply with
    the requirements of QGEWC (E) Regulations.
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    3 The connection to metalwork shall be made internally to a secure terminal on a part of the
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    enclosure which is a permanent fixture. The terminal shall be constructed of a material which
    will minimise chemical corrosion resulting from contact with the protective conductor or other
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    metal part. Conductor terminations shall be by the use of soldered or crimped connectors or
    screwed terminations, or other approved methods.

    4 Earth and other protective conductors shall be selected and installed so that they comply with
    the QGEWC (E) Regulations for Electrical Installations, the BS 7430, BS 7671 and the
    Regulations for Protective Multiple Earthing where appropriate. All protective conductors
    shall be colour coded green/yellow stripe. Where protective conductor is part of a multicore
    cable and a green/yellow stripe colour coded core is not available, the Contractor shall
    ensure that the protective conductor is adequately identified. Each cable shall enter the
    controller housing via a stuffing gland in the gas plinth gland plate. The stuffing gland shall be
    so designed as to prevent the diffusion of gas and support the cable. The earth stud of the
    cable terminator shall be correctly bonded to the earth bar in accordance with the QGEWC
    (E) Regulations, using a 6.00 mm2 conductor (2.50 mm2 for loop feeder cables).

    5 The earthing requirements at the head of each traffic signal pole shall be as follows:
    QCS 2014 Section 06: Road Works Page 15
    Part 16: Traffic Signals

    (a) the earth terminal of the gland, shall be connected to the earth terminal of the pole
    with a protective earth conductor correctly terminated with crimp connectors and
    having a minimum cross-sectional area of 6.00 mm2

    (b) the protective conductors from each signal head, pedestrian head, push-button unit or
    other equipment shall be connected together at the head of each pole and connected
    to the earth terminal in the controller housing by means of one dedicated core of the
    armoured signal cable servicing that pole
    (c) the earth connection at the head of the pole specified in (b) above, shall be connected
    to the earth stud of the pole with a bonding conductor having a minimum area of
    6.0 mm2 and by means of a crimped connector, or similar

    (d) push-button units fixed to a signal pole shall be earthed to the earth stud of the pole
    with a separate protective conductor terminated with crimp connectors and having a

    .
    minimum cross-sectional area of 6.00 mm2

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    (e) There shall be electrical connections by means of conductors having a copper

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    equipment cross-sectional area of not less than 6.00 mm2 between the earthing
    terminal and all metal structures, metal pipes and other metalwork (not being

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    metalwork forming part of a telegraphic, telephone or signalling circuit) which
    are, or may reasonably be expected to become, in electrical contact with the
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    general mass of earth
    (ii) are so situated that simultaneous contact may reasonably be expected to be
    made by any person with such structures, pipes or other metalwork (or any
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    metalwork in electrical contact therewith).


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    These connections shall be made as near as practicable to locations where users or


    maintenance staff approach the facility.
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    16.3.6 Permanent Electrical Power Supply


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    1 The Contractor shall be responsible for liaison with QGEWC (E) to provide a power supply to
    the traffic signal controller and shall be responsible for all works required to provide this
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    supply.
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    2 The electricity supply shall be 240 V AC 50 Hz single phase.


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    3 The Contractor shall organise, with the approval of QGEWC (E), one of the following earthing
    systems:

    (a) TN-S System. Where QGEWC (E) will provide an earthing point which affords a
    continuous metallic return path to the earth of the supply system. The Contractors
    earthing conductor shall be connected to this point
    (b) TN-C-S System (PME). Where QGEWC (E) will provide a combined neutral earth
    supply. The earthing Contractors earthing terminal and a lead from the earth terminal
    shall be left available for the QGEWC (E) to connect to the incoming supply. A similar
    neutral conductor lead shall also be left available for the same purpose
    (c) TT System. Where a means of earthing will not be provided by the QGEWC (E) the
    earthing terminal will be connected to an effective earth electrode compliant with the
    QGEWC (E) Regulations for Electrical installations. Where the TT System is provided
    by the QGEWC (E) the Contractor shall install an earth leakage circuit breaker to
    comply with the QGEWC (E) Regulations.
    QCS 2014 Section 06: Road Works Page 16
    Part 16: Traffic Signals

    4 The Contractor shall ensure that the equipment complies in all respects with the regulations
    and requirements of the QGEWC (E).

    5 The Contractor shall be responsible for all cable laying and jointing.

    6 It shall be the responsibility of the Contractor to inform the Engineer of the earliest date when
    he will be ready for the QGEWC (E) to make the service connections.

    7 The Contractor shall supply the equipment to be terminated to the QGEWC (E) service with
    phase and neutral conductors of not less than 4 mm2 and earthing conductor of not less than
    6 mm2. The QGEWC (E), shall connect the controller conductors and earth conductor to the
    terminal provided by the QGEWC (E).

    8 The QGEWC (E) cut-out shall incorporate a high breaking capacity fuse carrier and fuse to
    BS 88 or BS 1361 of the correct rating. The rating shall be specified by the Contractor to

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    comply with the type requirements of the QGEWC (E) Regulations. The maximum

    .l.
    permissible earth fault loop impedance shall be those stated in the QGEWC (E) Regulations.

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    16.3.7 Inductive Loops for Vehicle Detection

    1
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    Slot cutting shall be carried out by a specialist subcontractor. The Contractor shall be
    responsible for marking out all slot configurations and shall supervise the work of the
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    subcontractor. The slot cutting subcontractor shall make arrangements to provide an
    adequate water supply to enable him to carry out the necessary works. The approximate
    as

    position of inductive loops and route of feeder cables will be as designated. The Contractor
    shall specify the loop configurations at each site, the detailed layout of individual loops and
    se

    the number of turns per loop. This information shall be supplied to the Engineer. When loop
    configurations are specified by the Engineer, such information as required will be supplied to
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    the Contractor. In order to obtain a high standard of installation, the Contractor's staff and
    subcontractors shall be fully briefed by the Contractor and given written instructions
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    describing the technical requirements of this specification and method of installation. This
    shall cover depth and preparation of slots, backfilling, jointing, ducting under kerbs, earthing
    and commissioning of equipment.
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    2 Subsurface detector housings for loop detection equipment are not acceptable to the
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    Engineer. Detector housings shall be positioned so as to reduce the possibility of damage in


    the event of a road traffic accident and shall not present an obstruction or visual intrusion. In
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    cases of doubt, the advice of the Engineer shall be sought. Positions of detector housings
    shall be to the approval of the Engineer. Where a remote detector housing is used, each one
    shall be connected to the controller by 'Twinflex' cable. The cable will be ducted to the
    controller unless the Engineer's agreement is obtained to cutting a slot in the carriageway.
    Voltages on this cable shall not exceed 50 V AC or 120 V DC whether between conductors or
    to earth. The Contractor shall provide two sets of keys to all equipment housing supplied as
    initial issue. The Contractor shall be responsible for removing all surplus materials from site
    at the completion of the works.
    QCS 2014 Section 06: Road Works Page 17
    Part 16: Traffic Signals

    3 The cable specified may in exceptional circumstances be replace with an armoured multicore
    cable (i.e.. triple vehicle extensions with speed discrimination) double vehicle extensions with
    speed assessment. The cable specified shall be terminated at the controller with a cable
    gland or castellated bar approved by the Engineer. The gland shall be bonded to the earth
    point using a 4 mm2 flexible earthing cable terminated with crimp connection tags. The
    remote end of the cable shall be connected to the plate and 4 mm2 flexible earthing cable
    terminated with crimp connection tags or by other means approved by the Engineer. In
    addition one core of the armoured cable shall be used as an earth continuity conductor and
    shall be bonded to the earth point on the controller and to both the equipment earth and the
    metalwork of the housing at the remote end of the cable. The cable specified shall be
    provided with a minimum of 25 percent spare conductor capacity (armoured and non-
    armoured multicore cables only).

    4 The detector shall operate satisfactorily with a feeder up to 100 metres in length. The feeder
    is defined as the cable between the loop tails and the detector housing. Where adjustments

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    are required to sensitivity and presence time, these shall be made during initial setting-up and

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    no further adjustments shall be necessary. The equipment, including loop and feeder, shall

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    operate correctly within all carriageways of reasonable condition without any reduction in
    performance as follows:

    (a) air temperature (-10C to 60C)


    ta
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    (b) relative humidity up to 100 % (non-condensing)
    (c) carriageway flooded under 1 cm water, or dry
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    (d) carriageway subjected to continued heavy use by buses and heavy goods vehicles
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    (e) sidewalk and kerbs subjected to misuse by vehicles


    (f) feeder assumed to be buried in soil or sand which may be dry or wet
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    (g) the detector shall not operate from electrical noise pick-up on the loop or feeders.
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    5 Slot-cutting operations shall not be conducted in wet weather. Wet weather to be defined as
    such conditions where the Engineer considers it would be unsafe to carry out slot cutting
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    operations. Slots shall be cut using a motorised machine fitted with a diamond saw blade.
    it

    The layout of the loop configuration shall avoid areas of poor reinstatement in the road
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    surface caused by other roadworks or works. Slots shall be cut at least one metre from any
    such disturbance. Slots shall be cut at least one metre from any ferrous objects such as
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    manhole covers. In concrete road surface, the Contractor shall not cut slots less than 1.5
    metres from transverse joints between adjacent concrete sections. The depth of loop slots
    shall be (50 + 7.0 n) mm with a tolerance of + 10.0 mm / - 0.0 mm. In concrete surfaces the
    depth shall be (25 + 7.0 n) mm with a tolerance of + 5.0 mm / - 0.0 mm where 'n' is the
    number of cables and the first figure is the minimum depth of cover. The depth of each slot
    shall be checked with a depth gauge along the whole length of the slot. The Contractor shall
    ensure that there are no irregularities in the base of the slot. Where an angle more acute
    than 13 degrees in formed at the junction of two adjacent loop slots, then the slot junction
    shall be truncated with a saw cut at the apex of the junction; i.e., one blade thickness from
    the inside edge of the slot corner, and this cut shall be to the same depth as the adjoining
    slots. The junction shall not be truncated with a cold chisel. Slots cut for feeder cables shall
    be 20 mm wide (core cables 25 mm) with a tolerance of 3 mm, to give a cover of 65 mm in
    bituminous surfaces (45 mm in concrete surfaces) with a tolerance of + 10.0 mm / -0.0 mm.
    Only one feeder cable shall occupy each slot.
    QCS 2014 Section 06: Road Works Page 18
    Part 16: Traffic Signals

    6 The loop feeder cables shall take the most direct route to the indicated cable chamber. This
    slot is specified as being 20 mm wide, therefore care shall taken not to obliterate any road
    markings in whole or part. In the first instance the most direct route from the loop position to
    the kerb line shall be taken. The loop feeder cables shall be joined in the carriageway only
    with the approval of the Engineer. The joint slot shall be 10 mm wider and 10 mm longer than
    the overall dimensions of the completed joint. The depth of the slot shall be sufficient to give
    a minimum 40 mm cover above the joint. The joint slot shall be positioned either at a traffic
    lane boundary or at crown of the road so that it is not subjected to the maximum stresses
    exerted by road vehicles. Each loop shall be separated from adjacent loops by a minimum of
    100 mm. The Contractor's supervisory staff shall check the quality of workmanship before
    laying cable and backfilling. All debris and slit shall be cleared from the base of the slot and
    the slot blown dry with compressed air before cable laying.

    7 For laying loop cables the cable shall be dry before installation. The Contractor shall ensure
    that the cable lies evenly in the bottom of the slot, and shall secure the cable in such a

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    position if necessary. Sharp implements shall not be used to seat the cable in the slot. Loop

    .l.
    tails shall not extend more than 20 metres from the loop before being joined to the feeder

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    cable. Loop tails shall be twisted. Each twisted tail shall have a dedicated slot to the joint with
    feeder cable. Loop tails shall normally be joined to the feeder cable within cable inspection
    chambers. Cables shall not be bent to a radius of less than 12 times their diameter or less
    ta
    than a radius recommended by the manufacturer whichever is the greater. Where cables
    qa
    enter the sidewalk a small area of carriageway is to be excavated and a uPVC duct laid
    through the kerbs for each feeder cable. The duct shall be level with the base of the slot from
    which the feeder cable emerges. The excavated area shall be backfilled with fine aggregate
    as

    concrete to the duct invert level. The cables shall then be backfilled with compacted fine cold
    asphalt and hot oxidised bitumen R85/40. The kerb stone shall be reinstated. Feeder cables
    se

    in soft verge or beneath sidewalks are to be laid in ducts at a minimum depth of 500 mm
    below ground level unless otherwise specified by the Engineer. Feeder cables laid unducted
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    in trenches shall be laid on a 75 mm bed of sand free from stones and other sharp materials
    with a further 75 mm of similar sand placed over the cable. Where feeder cables are laid
    ov

    unducted in soft verges, the cable position shall be indicated with a plastic warning tape laid
    at a depth of 150 mm to 200 mm from ground level and vertically above the cable. The tape
    o

    shall be printed with suitable warning message repeated at one metre intervals. Where
    it

    feeder cables are required to cross French drains or other coarse bed materials in central
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    reservations, the cable shall be looped and protected with flexible plastic ducting. Ducting is
    to be provided by the installation Contractor.
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    8 Cable joints shall be approved by the Engineer. Feeder cables shall be electrically connected
    to the loop tails with insulated crimp connector using a ratchet type of crimping tool. The
    Contractor shall ensure that the cable conductor has been correctly crimped by visually
    checking the cable and also by applying a vigorous pull test to the cable on either side of the
    joint. The electrical connectors shall be encased in a joint approved by the Engineer and the
    Contractor shall ensure that the connectors are staggered to avoid the possibility of any short
    circuits. The Contractor shall ensure that any instructions issued by the cable joint
    manufacturer are provided in writing to his installation and supervisory staff. These
    instructions shall form part of this specification. The Contractor shall ensure that the joint is
    waterproof before backfilling. With the exception of cable joints between loop and feeder
    cables, no other joint shall be permitted in the loop/feeder configuration. Cables shall be
    terminated in the controller or detector housing using terminal connection blocks which are
    adequate in size for the diameter of conductors used. Screws shall not bear directly onto
    conductors, either a protective leaf in the terminal or a crimped pin on the end of the
    conductor shall be used.
    QCS 2014 Section 06: Road Works Page 19
    Part 16: Traffic Signals

    9 Immediately before backfilling, the Contractor shall ensure that all slots are clean and dry and
    that all silt and debris has been removed from the base of the slot. Loop slots shall be
    backfilled with a low viscosity epoxy resin, approved by the Engineer, to give a minimum of
    10 mm cover above the uppermost cable. The resin specified shall be poured at a viscosity
    of between 500 and 1000 pascal seconds. The Contractor shall provide the Engineer
    documentary evidence from the resin manufacturer of the temperature necessary to achieve
    this viscosity. The Contractor shall satisfy the Engineer, before epoxy resin operations
    commence, that the specialist subcontractors on-site equipment is able to raise the epoxy
    resin and maintain it at the temperature necessary to achieve the viscosity specified. The
    remaining volume of loop slot shall be backfilled with blown grade hot oxidised bitumen to the
    level of the road surface. Feeder cable slots shall be backfilled with fine cold asphalt
    compacted around the cable. The upper 20 mm of the slot shall be filled with hot oxidised
    bitumen. Joint slot shall be backfilled with epoxy resin to a level 10 mm above the completed
    joint. The remaining volume shall be filled with hot oxidised bitumen. The hot oxidised

    .
    bitumen specified shall be heated to a pouring temperature of 185 C and shall be poured

    l
    .l.
    from an enclosed container which shall be preheated before use. The fine cold asphalt

    rw
    specified shall comply with the requirements of BS EN 13108. The asphalt shall be soft and
    easily worked when applied, and shall be hand compacted to the satisfaction of the Engineer.
    Alternative compounds proposed by the Contractor shall be approved by the Engineer.

    10 ta
    The contractor shall be responsible in determining the exact location of the loops and shall
    qa
    supervise the work of the sub-contractor. The sub-contractor shall mark the locations of the
    performed inductive loops. Each shall be separated from adjacent loops by a minimum of
    as

    100mm and shall be laid on top of the road base or 230mm form the road surface.
    se

    11 The cable shall be dry before installation. The sub-contractor shall lay the performed
    inductive loops and stretch it as per the marked locations. The T-joint of the loops shall be
    positioned to the nearest chamber/pull box/detector hand hole. The loops shall be fixed by
    er

    using a clamps and nails to achieve the desired shape


    ov

    12 The loop wires from the preformed loop to the adjacent chamber/pull box/detector hand hole
    shall be twisted together into a pair with minimum of three turns per 305mm and encased in
    o

    polypropylene conduit and/or 2250 psi hydraulic hose between the performed loop and the
    it

    adjacent chamber/pull box/detector hand hole. Lead-in conduit shall be 100% injected with
    et

    hot asphalt sealant to prevent the entrance of water at the chamber/pull box/detector hand
    hole.
    m

    13 Asphalt shall be manually laid around the loops to protect it from the pavement
    machine/equipment.

    14 Upon completion of the installation works, the Contractor shall lay the asphalt on the entire
    carriageways by using the approved pavement machine.

    15 Each loop shall be tested sequentially by three methods: by megger (measured by mega
    ohms), by resistance (in ohms), by inductance (measured in micro henries).

    16 In case of existing pavement, a groove shall be cut by using a slot cutting machine. The
    frames and home-runs shall be placed into the cuts. The cuts shall be filled with hot melted
    asphalt-rubber sealant conforming to the manufacturers recommendations.

    17 All the installation works shall conform to the manufacturers specifications.


    QCS 2014 Section 06: Road Works Page 20
    Part 16: Traffic Signals

    16.4 TESTING AND COMMISSIONING

    1 Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
    acceptance test in his workshop. The programmed and internally complete controller shall
    be connected to a labelled light board capable of simulating all traffic signal aspects
    controlled by that particular controller. The Contractor shall ensure that all equipment and
    devices are available to show that the controller fully complies with operational requirements.
    The factory acceptance test shall consist of the following checks:

    (a) visual check of internal wiring and controller assembly


    (b) operation of green conflict monitor
    (c) intergreen times
    (d) group times

    l .
    (e) detector logic (where applicable)

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    (f) stage to stage change logic

    rw
    (g) lamp switching.

    2
    ta
    All traffic signal equipment shall be commissioned to the satisfaction of the Engineer.
    qa
    3 It shall be the responsibility of the Contractor to supply all equipment and personnel required
    to commission the traffic signal equipment.
    as

    4 On completion of installation, and before commissioning, the Contractor shall undertake the
    following tests to the satisfaction of the Engineer and in accordance with the QGEWC (E)
    se

    Regulations.
    er

    (a) visual inspection


    ov

    (b) continuity test of all protective conductors


    (c) insulation resistance test; insulation resistance shall not be less than 100 megaohms
    o

    (d) polarity check


    it

    (e) earth loop impedance test.


    et

    5 Where a residual current circuit breaker is installed, tests in accordance with the QGEWC
    m

    (E) Regulations shall be complied with. The Contractor shall provide the equipment
    necessary to complete the tests and shall provide all other test equipment to demonstrate
    that the installation is compliant.

    6 After the traffic signal and controller equipment is installed on site and after it is connected to
    all its associated equipment, the Contractor shall arrange for a site acceptance test. The site
    acceptance test will recheck all the points covered in the factory acceptance tests and in
    addition shall include visual and electrical tests on all posts, gantries, heads, push-buttons
    and cabling. The Contractor shall ensure that the area of site covered by the installation
    being tested is cleared of all debris, plant and machinery. The Contractor shall be
    responsible for the supply of any personnel required to conduct the site acceptance test. The
    Contractor shall provide any vehicles required to conduct the site acceptance test. The
    Contractor shall ensure that all equipment and devices are available to show that the
    controller fully complies with the operational requirements.
    QCS 2014 Section 06: Road Works Page 21
    Part 16: Traffic Signals

    7 Each loop and feeder configuration of the vehicle detection system shall be tested as follows
    and the results given in a test certificate for the loop installation. This certificate shall include
    all pertinent information for the testing. The Contractor shall submit a pro-forma certificate to
    the engineer before carrying out the commissioning.

    (a) With the loop circuit disconnected from the detector, the impedance to earth of the
    two loop and feeder conductors shall be measured at a test voltage of 500V DC
    applied for at least one minute. This shall not be less than 10 megaohms. The two
    ends of the loop circuit shall be connected together for this test
    (b) With the armouring of the feeder cable disconnected from the earth point, the
    impedance to earth of the armouring shall be measured at a test voltage of 500V DC
    applied for one minute. This shall not be less than 10 megaohms
    (c) With the armouring of the feeder connected to the earth point of the equipment
    housing, the impedance to earth of the armouring shall be measured. This impedance

    l .
    shall not be greater than 0.5 ohms

    .l.
    (d) The inductance of the loop and feeder circuit shall be measured. This shall be

    rw
    comparable with the theoretical value previously supplied to the Engineer
    (e) The frequency of operation of each configuration shall be measured. Where two loop

    ta
    circuits share a common feeder cable their frequency of operation shall be separated
    by at least 5 kHz
    qa
    (f) The Contractor shall adjust the sensitivity and presence time of each detector to the
    requirements specified by the Engineer. The Contractor shall demonstrate correct
    as

    operation of the detector at the sensitivity specified


    se

    (g) The Contractor shall ensure that an inductance change caused by vehicles in one
    loop shall not induce spurious observations in any adjacent loop system.
    er

    8 Any loop or feeder which fails these tests shall be replaced by the Contractor at his expense.
    ov

    9 Upon satisfactory completion of the factory acceptance and site acceptance tests, and when
    the Engineer is fully satisfied that correct installation and adherence to the operational
    o

    requirements has been attained. The PWA will issue a final commissioning certificate. The
    it

    installation, or any part thereof shall not be opened to general traffic until this certificate is
    et

    received.
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    16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT

    16.5.1 General

    1 During the initial maintenance period complete record of component failures shall be kept by
    the Contractor in order to provide information on the reliability of various components.

    16.5.2 Operational Maintenance

    1 The Contractor shall provide full operational maintenance coverage for a period of 400 days
    subsequent to the issuance of the final commissioning certificate.

    2 The Contractor shall use only maintenance contractors approved for this work by the PWA.
    QCS 2014 Section 06: Road Works Page 22
    Part 16: Traffic Signals

    3 During the maintenance period, the Contractor shall be responsible for providing coverage for
    the following:

    (a) Replacement or repair and installation of any failed equipment


    (b) Daily corrective maintenance
    (c) Quarterly maintenance
    (i) Check the cycle length, green time, intergreen time and all other signal timing
    parameters as given in the timing chart.
    (ii) Check the timings of the different signal programmes and test the switch over
    them manually and by time clock.
    (iii) Test loop detectors for activation and re-tune if necessary.
    (iv) Test ELCB and any other circuit breakers.
    (v) Replace any items that show significant wear and/or are operating outside of the
    manufacturers tolerances.
    (vi) Test operations of pedestrian push buttons

    l .
    (vii) Check timing of Flashing Units

    .l.
    (viii) Service controller in accordance with manufacturers specifications
    (ix) All signal heads, reflectors, optical lenses and backing boards shall be cleaned

    rw
    (both internally and externally) in accordance with the manufacturers
    specifications
    (d)
    ta
    (Bi-annual maintenance - The following works are to be carried out in addition to those
    described in section (c)
    qa
    (i) All protective earth conductors shall be inspected and tested.
    (ii) All lamp fittings and connectors shall be dismantled and cleaned.
    (iii) Signal heads shall be checked for correct alignment and all brackets and
    as

    clamps tightened.
    (iv) All electrical connectors are to be checked and cleaned where necessary.
    se

    (e) Annual maintenance - The following works shall be carried out in addition to those
    described in sections (c) and (d)
    er

    (i) All signal poles and gantries shall be painted and renumbered. The signal poles
    and gantries shall be coated with primer, red-oxide, and two coats of colour grey
    ov

    paint. The paint specification/colour shall be approved by the Engineer.


    (ii) All inspection chambers shall be cleaned properly.
    o

    (iii) Timings for all signals shall be altered as directed by the Engineer at the
    beginning and end of the month of Ramadan.
    it

    (iv) Minor changes to the controllers operational configuration (Changing of phasing


    et

    /staging, green times and intergreen times) as deemed necessary by the PWAs
    traffic signal engineer.
    m

    4 The Contractor shall ensure that personnel are available to maintain equipment such that
    failed equipment shall be replaced or repaired within four hours of notification of the fault.
    Where controller configuration changes are required, the Engineer shall allow a reasonable
    period for the Contractor to respond.

    5 Failed equipment shall be replaced/repaired within 4 hours of notification of the fault.

    6 Where controller configuration changes are required, the Engineer shall allow a reasonable
    period for the Contractor to respond.
    QCS 2014 Section 06: Road Works Page 23
    Part 16: Traffic Signals

    16.5.3 Emergency Maintenance

    1 In the case of accidental damage or 'knock downs' or any other equipment failure deemed to
    be outside of the Contractors control, shall not be required to take responsibility for repair or
    replacement. However it shall be the Contractors responsibility to provide the immediate on-
    site response to a police or the PWA request.

    2 Upon the PWA having effected a remedy to any emergency maintenance requirement, it
    shall be the Contractors responsibility to ensure that all repairs or replacements have been
    conducted to a standard such that no warranties become invalid.

    3 If the Contractor feels that any repair or replacement is not of sufficient standard to maintain
    his warranty he shall notify the PWA with 14 days of any such repair or replacement having
    been conducted.

    l .
    16.5.4 Contractors Vehicles

    .l.
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    1 The Contractor shall arrange a vehicle mounted hydraulic platform with boom and any
    additional vehicle for the use of his staff whenever required throughout the maintenance
    period.

    2 ta
    The vehicles shall be provided with a flashing amber roof light array.
    qa
    3 The contractor shall be responsible for any cost associated with the vehicles.
    as

    4 The hydraulic platform shall be capable of performing the required vertical and horizontal
    se

    manoeuvres safely and satisfactorily, including adequate platform capacity and boom
    articulation.
    er

    5 The contractor shall gain approval from the Engineer as to the vehicle acceptability prior to
    ov

    supplying the said vehicle.

    16.5.5 Contractors Equipment


    it o

    1 The Contractor shall be responsible for supplying any regular or special equipment or tools
    et

    required for the satisfactory undertaking of the works. In particular this shall include, but not
    limited to:
    m

    (a) Specialised commission/testing equipment for all the current traffic signal (Siemens,
    Futurit, Peek and Tyco) controllers to allow Factory Acceptance Tests (FAT) and Site
    Acceptance Tests (SAT).
    (b) Portable keyboard interfaces to allow interrogation and on-site programming of micro-
    processor signal controllers for all the traffic signal systems.
    (c) Workshop based aspect simulators to allow for Factory Acceptance Tests.

    END OF PART
    QCS 2014 Section 06: Road Works Page 1
    Part 17: Road Drainage

    17 ROAD DRAINAGE................................................................................................... 2
    17.1 GENERAL REQUIREMENTS .................................................................................. 2
    17.1.1 Scope 2
    17.1.2 References 2
    17.1.3 Quality Assurance 3
    17.1.4 Delivery, Storage and Handling 3
    17.2 DRAINAGE PIPES & PIPELINES ............................................................................ 3
    17.3 EXTENDING PIPELINES ........................................................................................ 4
    17.4 ROAD GULLIES ...................................................................................................... 4
    17.5 MANHOLE COVERS AND GULLY GRATINGS ...................................................... 4
    17.6 SOAKAWAYS ......................................................................................................... 5

    .
    17.7 SOAKAWAY BOREHOLES ..................................................................................... 6

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    .l.
    17.8 TESTING AND CLEANING SURFACE WATER DRAINS ....................................... 7

    rw
    17.9 TRENCH SOAKAWAYS .......................................................................................... 7
    17.9.1 General 7
    17.9.2
    17.9.3
    General
    Pipe ta 7
    7
    qa
    17.9.4 Geotextile Fabric 8
    17.9.5 Single Sized Coarse Aggregate 8
    as

    17.9.6 Catchpit Chambers 9


    17.9.7 Road Crossings 9
    se

    17.9.8 Geocellular Stormwater Attenuation / Soakaway Trenches 9


    The maximum installation depth, to base of units, shall normally not exceed the
    er

    height of 10
    17.9.9 Reinstatement above Trenches 10
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    17.9.10 Testing 10
    17.10 GEOCELLULAR TANKS ....................................................................................... 10
    o

    17.10.1 Geocellular Units 10


    it
    et

    17.10.2 Geocellular Tank Arrangement 10


    m
    QCS 2014 Section 06: Road Works Page 2
    Part 17: Road Drainage

    17 ROAD DRAINAGE
    17.1 GENERAL REQUIREMENTS

    17.1.1 Scope

    1 This Part includes:

    (a) stormwater drainage works draining the road carriageway and directly adjacent areas,
    including:
    (i) road and other pavement gullies and gully pots
    (ii) pipes of minimum 150mm diameter including bedding materials used to connect
    gully pots to inspection chambers and intermediate manholes

    l .
    (b) groundwater drainage using filter drains within the road corridor

    .l.
    (c) soakaways specifically related to road stormwater and groundwater collection and

    rw
    disposal
    (d) connections to stormwater drainage systems including culverts, open channels and
    closed stormwater drainage pipelines.
    ta
    qa
    (e) Geocellular attenuation and soakaway trenches and tanks.

    2 Related Sections and Parts:


    as

    This Section
    se

    Part 18 Geosynthetics
    er

    Section 5 Concrete
    Section 8 Drainage Works
    ov

    Section 20 Drainage Works for Buildings


    Part 3 External Drainage Works
    it o
    et

    17.1.2 References
    m

    1 The following standards are referred to in this Part:


    BS EN 124 ..................Gully tops & manhole tops for vehicular and pedestrian areas

    BS 4962 ......................Plastic pipes and fittings for subsoil drainage


    BS 5911 ......................Concrete pipes ancillary concrete products
    BS ISO 14654 ............Epoxy coated steel

    ISO 9001 ....................Quality assurance in production and installation

    BRE digest 365 - Soakaway Design


    QCS 2014 Section 06: Road Works Page 3
    Part 17: Road Drainage

    17.1.3 Quality Assurance

    1 The manufacturer of all manholes and gully gratings shall be accredited to a third party
    quality system such as ISO 9001. The supplier shall submit a copy of his accreditation
    showing the scope of products covered.

    17.1.4 Delivery, Storage and Handling

    1 All manhole covers and gullies shall be clearly marked with the technical standard of
    manufacture, the loading class, the name identification mark of the manufacturer and the
    mark of the certification body.

    17.2 DRAINAGE PIPES & PIPELINES

    1 The materials, manufacture, finish, installation inspection and testing of all drainage pipes

    l .
    and fittings for roadworks shall comply with the requirements of Part 3 of Section 20, except

    .l.
    as modified by this section of the specification.

    rw
    2 The type of pipe to be used and the diameter shall be as designated on the drawings or in the
    project specification.

    3 ta
    Pipes may be of vitrified clay, concrete, glass reinforced plastic or UPVC. Each of these pipe
    qa
    types shall meet the designated requirements for standards, materials, manufacture,
    strength, length and dimension of tolerances joints, workmanship and finish, inspection and
    basis of acceptance given in Part 3 of Section 20.
    as

    4 Unless designated otherwise only one type of pipe shall be used within any individual drain or
    service duct between consecutive chambers.
    se

    5 The Contractor shall ensure that plastic pipes are not subject to deterioration due to
    er

    exposure to sunlight between manufacture and installation in the ground.


    ov

    6 The excavation, bedding, laying and backfilling around pipelines shall be carried out in
    accordance with Part 2 of Section 8.
    o

    7 Soft spots below the bottom of an excavation shall be removed as directed by the Engineer
    it

    and the resulting void backfilled with granular material to the approval of the Engineer.
    et

    8 Any additional excavation below the bottom of the line required shall be made good with
    m

    granular material.

    9 The pipes shall be laid at the designated levels and gradients. The deviation in level from
    that designated at any point shall not exceed 20 mm unless agreed otherwise by the
    Engineer.

    10 Pipes shall be laid so that each one is in contact with the bed throughout the length of its
    barrel.

    11 Parts and fittings shall be examined for damage and shall be cleaned immediately before
    laying. Any pipes that are damaged shall not be used in the works.

    12 Measures shall be taken to prevent soil or other material from entering pipes and to anchor
    each pipe to prevent moving before the work is complete.

    13 The pipe bedding material shall be as designated on the project drawings or in the contract
    documents.
    QCS 2014 Section 06: Road Works Page 4
    Part 17: Road Drainage

    17.3 EXTENDING PIPELINES

    1 Where it is designated that existing drains are to be extended and connected to new drain
    chambers or channel, the connections shall be made during the construction of the new
    drain. The Contractor shall inform the Engineer in writing of the proposed position for the
    connection and the detail of the connection. The position of the connection shall be recorded
    by the Contractor on a drawing.

    2 The new connecting pipe shall be aligned such that the angle between the existing pipe and
    the new pipe is not greater than 60 %.

    3 Before entering or breaking into an existing drain, the Contractor shall obtain approval from
    the authority responsible for the pipeline.

    .
    17.4 ROAD GULLIES

    l
    .l.
    1 The type, position, dimensions and clear openings of gullies will be as designated on the

    rw
    drawings or in the project specifications.

    2
    ta
    Gullies shall be constructed so that no part of the spout or trap has a cross sectional area
    less than 2/3 that of the outlet.
    qa
    3 Precast concrete gullies shall comply with BS 5911 Part 2.
    as

    4 Cast iron and steel gully gratings shall be kerb type gullies complying with BS EN 124 unless
    se

    otherwise shown on the Contract Drawings.

    5 The upper surface of gully gratings shall be flat except where otherwise designated. Slots in
    er

    gratings or between gratings and frames shall not be orientated parallel to the direction of
    ov

    traffic, except where the slots are less than 150 mm long or less than 20 mm wide.

    6 The frames shall be bedded on a 1 to 3 cement sand mortar.


    it o

    7 Backfilling to precast gullies shall be carried out to formation level with general fill. Where
    et

    mechanical compaction is impractical, the backfill shall be concrete of the designated grade.
    m

    8 Gully connections shall be constructed of minimum 150mm diameter Unplasticised


    PVC (PVC-U) pipes in accordance with BS 4660 or ESVC pipes in accordance with BS EN
    295. Where required by the Engineer, these shall be bedded and surrounded with concrete
    with movement at the joints permitted by the insertion of compressible material which shall
    extend to the outside of the concrete surround.

    17.5 MANHOLE COVERS AND GULLY GRATINGS

    1 Manhole covers and gully gratings shall be formed from ductile iron with an element of
    graphite spheres to produce a molecular structure that gives the required tensile strength and
    shock load resistance.

    2 Drainage products may be produced from grey iron and shall be hard wearing, inherently
    stable and highly resistant to flexing.
    QCS 2014 Section 06: Road Works Page 5
    Part 17: Road Drainage

    3 The type of manhole cover; i.e., square, rectangular, double triangular, single cover shall be
    as designated on the drawings.

    4 During installation the frames shall be properly bedded and levelled to prevent rocking or any
    lateral movement of the frame.

    5 Covers and frames shall be kept together as a supplied unit and interchangeability between
    various covers and frames shall not be permitted.

    6 All castings shall be supplied with a black epoxy coating finish.

    7 The tops of all manhole covers shall have a non-slip surface to provide adequate grip.

    8 When so designated, the supplier shall arrange for specific lettering to be cast into the top of
    the covers. The lettering shall be up to a maximum of 4 letters or digits.

    .l
    .l.
    9 Manhole covers and gullies shall meet the requirements of BS EN 124, European Standard

    rw
    for access covers of gully tops for vehicular and pedestrian areas.

    10 All manholes covers and gullies supplied shall have been verified as being manufactured to

    ta
    BS EN 124 by third party assessment body for both quality procedures and technical
    qa
    requirements.

    11 The manholes covers or gullies shall meet one of the loading categories specified in BS EN
    as

    124.
    se

    Table 17.1
    Loading Categories for Manhole Covers on Gullies
    er
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    Class Loading, Tonnes


    A 15 1.5
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    B 125 12.5
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    C 250 25
    et

    D 400 40
    m

    12 For a manhole entry to sewer and surface / ground water manholes a minimum of 750mm
    square clear opening shall be provided. For entry to TSE chambers a minimum of 675mm
    square opening shall be provided.

    13 For manholes situated in the carriageway a three point cover seating shall be adopted to
    prevent any movement or rocking.

    14 Where hinged gully gratings are installed the edge with a hinge shall face the traffic to ensure
    the cover closes if inadvertently left opened and hit by traffic.

    17.6 SOAKAWAYS

    1 Soakaways shall be constructed using precast concrete rings. Concrete works shall comply
    with the requirements of Section 5 of the specification. Concrete shall be Grade C50 for the
    precast concrete rings and the cover slab, using Sulphate Resisting Portland Cement.
    QCS 2014 Section 06: Road Works Page 6
    Part 17: Road Drainage

    2 The cover slab shall be of the dimensions and contain the reinforcement as shown on the
    drawings or detailed in the Project Specifications.

    3 The structural concrete shall be designed for durability and shall include as a minimum the
    following specification:

    (a) minimum cover 40mm


    (b) all surfaces to be painted with an epoxy protective coating meeting the requirements of
    Section 5 Part 14 of the specification. The protective coating shall be factory applied
    to precast elements.

    4 The soakaways shall have an internal diameter of 1.8 m unless otherwise designated and
    shall be of a minimum depth of 3 m unless otherwise designated.

    l .
    5 The precast concrete rings shall be at least 150 mm thick and shall have three evenly spaced

    .l.
    lifting points.

    rw
    6 No permanently embedded metal parts shall be left with a cover less than 40 mm from the

    ta
    surface. The precast rings shall be constructed with 50 mm diameter holes at 400 mm
    centres in rows spaced 300 mm apart. The holes shall be alternately offset.
    qa
    7 The bottom ring shall be founded on insitu blinding concrete 200 mm deep.
    as

    8 The soakaway shall be surrounded by granular material which shall infill the whole void
    se

    between the soakaway and the undisturbed ground around the excavation.
    er

    9 The granular material shall be laid in tamps in 150 mm layers and shall nowhere be less than
    225 mm in width.
    ov

    10 The granular material shall be clean durable, sharp-angled fragments roughly cubical or
    o

    pyramidal in shape, of un-weathered rock of uniform quality graded and tested in accordance
    it

    with Tables 14.3, from a source approved by the Engineer


    et

    11 Cast iron covers and frames shall be to BS EN 124 of the designated loading class.
    m

    12 Geotextile material lining to the outside of the soakaway excavation shall be in accordance
    with Table 17.2 of this Section. The placing and laying of the material shall be in accordance
    with the manufacturers instructions and Part 15 of this Section.

    13 The geotextile material shall not be left exposed to the sun for a period greater than 7 days
    before burying.

    17.7 SOAKAWAY BOREHOLES

    1 The Contractor shall drill soakaway boreholes at the locations shown on the drawings. Unless
    designated otherwise the boreholes shall be 150mm diameter.

    2 Boreholes shall be initially taken to a depth of 20 m. At this depth the borehole shall be
    thoroughly flushed clean using compressed air and clean water.
    QCS 2014 Section 06: Road Works Page 7
    Part 17: Road Drainage

    3 The borehole shall then be completely filled with clean water and the rate of dissipation
    recorded. If the rate of dissipation is found to be less than required by the design criteria
    given in BRE digest 365 - Soakaway Design then the bore holes shall be deepened in 5 m
    depth increments and flushed until a satisfactory rate of dissipation is recorded. At the
    Engineers discretion the rate of dissipation maybe verified by a constant head permeability
    test using proprietary equipment to monitor and record the flow rate and the variation in water
    level within the borehole.

    17.8 TESTING AND CLEANING SURFACE WATER DRAINS

    1 Before completing of the road drainage part of the Works the Contractor shall systematically
    clean the whole road drainage system, in accordance with Section 8, Part 10, including
    gullies, connecting pipes and soakaways. The entire system shall be clear of debris and silts
    and in a sound working order.

    l .
    .l.
    2 Cast iron covers shall be freed from surfacing materials and pivot points shall be greased.
    The Contractor shall be responsible for cleaning up any silting of the surface water drainage

    rw
    system caused by other Contractors working within the Site and the approval of the
    Employer.

    3 ta
    A CCTV survey shall be carried out of the completed system in accordance with Section 8,
    qa
    Part 10 of QCS.

    17.9 TRENCH SOAKAWAYS


    as

    17.9.1 General
    se

    1 Trench soakaways shall be constructed in accordance with the dimensions and grades
    er

    shown on the Drawings. The trench soakaway consists of a perforated pipe or geocellular
    ov

    units laid in a trench. A geotextile fabric lines the trench or surrounds the geocellular units,
    with the remaining voids being filled with single sized coarse aggregate.
    o

    2 Reinstatement of trench soakaways shall be in accordance with the Contract drawings.


    it
    et

    17.9.2 General
    m

    1 Excavation for the trench shall be in accordance to the requirements of Part 3 of this Section.

    17.9.3 Pipe

    1 The pipe shall be a 300mm UPVC for installations outside the carriageway and 300mm
    ESVC for installations within the carriageway, perforated pipe supported on single-size
    coarse aggregate bedding. Pipe perforations shall be 10mm diameter in staggered rows
    around the circumference of the pipe with a pitch of 40degrees. The longitudinal spacing
    between each row of holes shall be 200mm.

    2 The manufacture, distribution, laying and jointing of perforated pipes shall generally be in
    accordance with the requirements of Section 8.
    QCS 2014 Section 06: Road Works Page 8
    Part 17: Road Drainage

    17.9.4 Geotextile Fabric

    1 Filter fabric material lining shall be non-woven geotextile manufactured from UV stabilised,
    high tenacity, virgin polypropylene fibres that have been both mechanically and thermally
    bonded and in accordance with Table 17.2.

    2 The placing and laying of the material shall be in accordance with the manufacturers
    instructions and Part 15 of this specification.

    3 The geotextile material shall not be left exposed to the sun for a period greater than 7 days
    before burying.
    Table 17.2
    Properties of Geotextile Material
    Mean Value

    .l
    Property Test Method Unit (Applied

    .l.
    (a)
    Tolerance )

    rw
    Tensile Strength EN ISO 10319 kN/m 8.0 (-0.8)

    Tensile Elongation
    ta
    EN ISO 10319 % 60 (20)
    qa
    CBR Puncture Resistance EN ISO 12236 N 1500 (-150)

    Cone Drop EN ISO 13433 mm 38 (+6)


    as

    Pore Size Mean AOS EN ISO 12956 m 75 (20)


    se

    2
    Permeability (H50) EN ISO 11058 l/m s 90 (-27)
    er

    2
    Weathering 50MJ/m Exposure (1 month EU) EN 12224 % >90
    ov

    Microbiological resistance EN 12225 % No loss


    o

    Resistance to acids & alkalis EN 14030 % No loss


    it

    Oxidation at 85 days (100 years) EN 12226 % >90


    et
    m

    Thickness @ 2kPa EN ISO 9863-1 mm 1.1


    (a)
    Note: Applied tolerances are based on 95% Confidence limits

    17.9.5 Single Sized Coarse Aggregate

    1 The trench shall be filled by granular material, which shall infill the whole width of the trench
    between the undisturbed ground trench sides, or between the geocellular units and the
    undisturbed ground, as shown on the drawings. The granular material shall be laid and
    tamped in 150 mm layers using mechanical plate compactors. For geocellular unit trenches
    the backfill shall be brought up in even layers such that the backfill material does not differ by
    more than 150mm in level between sides.
    QCS 2014 Section 06: Road Works Page 9
    Part 17: Road Drainage

    2 Where geotextile fabric is required to interface between the trench side walls and subgrade
    and the soakaway trench fill material, the width of the geotextile must include sufficient
    material to conform to trench perimeter irregularities and for a 150mm top overlap. When
    overlaps are required between rolls, the uphill roll should lap a minimum of 500mm over the
    downhill roll in order to provide a shingled effect. Care shall be exercised to prevent natural
    or fill soil from intermixing with the trench granular material. All contaminated granular fill
    shall be removed and replaced with clean material.

    3 The granular material shall be clean, durable, sharp-angled fragments roughly cubical or
    pyramidal in shape, of un-weathered rock of uniform quality and meet the grading limits in
    Table 17.3. The materials source shall be approved by the Engineer based upon the
    properties of the materials in accordance with the testing requirements as per Table 17.4.
    No reactive carbonate rock or sources with indication of local ground water contamination
    shall be used.

    .
    Table 17.3

    l
    .l.
    Grading Limits for Granular Material

    rw
    BS sieve size (mm) % passing by weight

    37.5
    ta100
    qa
    20 60 - 90
    14 5 - 30
    as

    10 0.2 - 1
    5 0
    se

    17.9.6 Catchpit Chambers


    er

    1 Catchpit chambers shall be constructed to the dimensions and at the spacing shown on the
    drawings.
    ov

    2 Chambers shall consist of rectangular precast concrete sections with internal dimension 800
    o

    x 1500mm. All concrete works shall comply with the requirements of Section 5 of the
    it

    specification. Concrete shall be Grade C50. Sulphate Resisting Cement shall be used.
    et

    Chambers shall also conform in all respects to the requirements for surface water drainage
    manholes in Section 8.
    m

    3 All surfaces to be painted with an epoxy protective coating meeting the requirements of
    Section 5 Part 14 of the specification. The protective coating shall be factory applied to
    precast elements.

    17.9.7 Road Crossings

    1 Where the trench soakaway crosses a road then non-perforated pipe shall be used extending
    1.0 meters beyond the road kerb line.

    17.9.8 Geocellular Stormwater Attenuation / Soakaway Trenches

    1 Loads on modular geocellular unitsThe permanent vertical loads to be carried by the units
    shall be determined by the designer

    (a) Lateral loads


    (b) Maximum installation depth
    QCS 2014 Section 06: Road Works Page 10
    Part 17: Road Drainage

    17.9.9 The maximum installation depth, to base of units, shall normally not exceed the height
    of Reinstatement above Trenches

    1 Reinstatement material above the trenches shall be of suitable fill, cement bound granular
    material, foamed concrete pavement materials or asphalt, or as appropriate in accordance
    with the Contract drawings, and shall be constructed in accordance with QCS Section 6.

    17.9.10 Testing

    1 On completion of each length of trench soakaway the Contractor shall carry out an infiltration
    test. The test shall be carried between completed catchpit chambers. The 2 No. upstream
    outlet pipes within the catchpit chamber shall be sealed and the chamber filled with water to a
    minimum depth of 1.5 metres. The depth of water shall be recorded each hour for the first
    twelve hours of the test and subsequently at time intervals as directed by the Engineer.

    l .
    2 The Contractor shall record the results of the test on a standard proforma and present these

    .l.
    to the Engineer on completion.

    rw
    17.10 GEOCELLULAR TANKS

    17.10.1 Geocellular Units


    ta
    qa
    1 Geocellular units used to form storm water attenuation tanks and soakaway tanks shall be in
    accordance with clause 14.9.8.
    as

    17.10.2 Geocellular Tank Arrangement


    se

    1 Locations for geocellular tanks


    er

    Geocellular tanks made up of geocellular units are suitable for installation in the following
    locations:
    ov

    (a) Public open spaces: beneath landscaped areas and paths. The landscaping scheme
    o

    for the park shall be considered when assessing the loads upon the tank.
    it

    (b) The vehicular access to the tank shall be restricted so as to exclude large vehicles, in
    et

    excess of the design vehicle load, from the area above the tank.
    m

    2 Loads on modular geocellular units


    The design of tanks constructed using modular geocellular units shall:-

    (a) take account of all applied loads, including accidental loading


    (b) be based on appropriate laboratory tests
    (c) use appropriate factors of safety
    (d) analyse all appropriate limit states (or failure modes)
    The determination of the loads to be carried by the geocellular units shall be determined in
    accordance with the requirements of BD 31/01.

    3 Permanent loads.

    4 Accidental loads
    QCS 2014 Section 06: Road Works Page 11
    Part 17: Road Drainage

    The risk of accidental loading occurring shall be assessed in the design process. Public
    parks may be occasionally inadvertently trafficked by HGVs and landscaped area can be
    used to park cars. Hard paved area shall be assumed liable to support such occasional
    accidental loading and geocellular tanks shall be designed to support accidental loading
    without risk of collapse.

    Location Risk

    Landscaped area in Specialist vehicles used for maintenance of geocellular tank and
    public park any separation system upstream of the tank
    Illegal parking of private vehicles
    Movement of delivery vehicles to kiosks in parks
    Large vehicles used for routine maintenance within park

    l .
    .l.
    Specialist vehicles used for erection / maintenance of lighting
    systems

    rw
    Erection of marquees / tents / stages / portable cabins for public
    events

    ta
    Large vehicles delivering equipment for public events
    qa
    Cranes for installation of equipment
    Generators used for public events
    as

    Planned parking of private vehicles during public events


    Access for emergency vehicles fire engines
    se
    er

    If the tank has not been designed to carry accidental loading then special precautions may be
    required to prevent it occurring. In public parks, the area above a tank shall be fenced off or
    ov

    have other barriers / landscaping to prevent vehicle access. Warning signs shall be provided
    to state that there is an area with limited load bearing capacity and restricted access for
    o

    vehicles.
    it

    The location of the tank and any loading restrictions shall be clearly identified in the operation
    et

    and maintenance manual for any facility.


    m

    5 Lateral loads
    The lateral loads on the units due to earth and water pressure shall be assessed and allowed
    for by the designer in accordance with the requirements for the design of retaining walls
    given in BS 8002:1994.

    6 Flotation or uplift
    Where the tank system is located below the water table, the uplift force shall be resisted by
    the dead weight of fill above the tank. Other surcharges that are not permanent shall not be
    included in the assessment.

    The minimum factor of safety against flotation shall be 1.25.

    7 Minimum cover
    The minimum cover to units shall be as follows:
    QCS 2014 Section 06: Road Works Page 12
    Part 17: Road Drainage

    Landscaped areas: a minimum of 1.0m to allow for suitable planting over the tank.

    The design of landscaping should be undertaken at the same time as the design of the tank
    so that the impact of tree roots can be considered. Trees should not be located closer than
    the canopy width at mature height from the tank. Trees should not be planted directly over a
    tank or in such a position where maintenance work would require the removal of the tree.

    8 Maximum installation depth


    The maximum installation depth, to base of units, shall normally not exceed the height of
    three units, plus the cover as assessed in Sub-Clause 15.

    9 Limit state design


    Modular geocellular tanks shall be designed as structural components, using limit state

    l .
    structural design theory in accordance with Section 4.1 of CIRIA Report C680 and BD 31/01.

    .l.
    The design philosophy shall follow the requirements for geotechnical design practice as

    rw
    described in Eurocode 7 (BS EN 1997-1:2004).

    END OF PART
    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Road Works Page 1
    Part 18: Geosynthetics

    18 GEOSYNTHETICS ........................................................................................ 2

    18.1 GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS ........................ 2


    18.1.1 Scope 2
    18.1.2 References 2
    18.1.3 Submittals 3
    18.1.4 Quality Assurance 3
    18.1.5 Guarantees and Warranties 4
    18.2 REQUIREMENTS FOR GEOTEXTILES ....................................................... 4
    18.2.1 General Requirements 4
    18.2.2 Drainage Applications 5
    18.2.3 Earthworks Applications 6

    l .
    18.3 GEOGRIDS ................................................................................................... 7

    .l.
    18.3.1 General Requirements for Geogrids 7

    rw
    18.3.2 Material Requirements for Geogrids 8
    18.3.3 Installation of Geogrids 9
    ta
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Road Works Page 2
    Part 18: Geosynthetics

    18 GEOSYNTHETICS
    18.1 GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS

    18.1.1 Scope

    1 This part of the specification covers the use of geotextiles and geogrids for the;

    (a) reinforcement of unbound aggregates for roads, hard standing and airfield pavements
    (b) reinforcement of embankment foundations over soft or weak soils
    (c) reinforcement of steep earthwork fills
    (d) reinforcement of retaining walls and bridge abutments

    .
    (e) repairs to earthworks embankment failures and landslides

    l
    .l.
    (f) for erosion control of slopes

    rw
    (g) for subsoil and sub-base drainage.

    2 Related Sections and Parts:


    This Section ta
    qa
    Part 3 Earthworks
    Part 4 Unbound Pavement Materials
    as

    Section 8, Drainage Works


    18.1.2 References
    se

    1 The following Standards and other documents are referred to in this part:
    er

    ASTM D 751 ...............Test Methods for Coated Fabrics


    ov

    ASTM D 5034 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
    (Grab Test)
    ASTM D 5035 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
    o

    (Strip Method)
    it

    ASTM D 4533 .............Test Method for Trapezoidal Tearing Strength of Geotextiles


    et
    m

    BS 8006......................Code of practice for strengthened/reinforced soils and other fills


    BS 2782......................Method of testing plastics
    BS 3502......................Symbols for plastics and rubber materials
    BS 4618......................Recommendations for the presentation of plastic design data
    BS EN ISO 10321 ......Geosynthetics
    BS EN ISO 10319 ......Geosynthetics

    DIN 54307 ..................CBR Test


    DIN 53854 ..................Weight Test
    DIN 53855 ..................Thickness Test

    ISO 9001 ....................Quality Management and Quality Assurance Standards

    Published Document (PD) 6533, Guide to Methods for Assessing the Durability of
    Geotextiles, British Standards Institute.
    QCS 2014 Section 06: Road Works Page 3
    Part 18: Geosynthetics

    18.1.3 Submittals

    1 The manufacturer shall submit comprehensive test results for the geosynthetic for the
    designated tests, which shall clearly indicate whether the values are mean values measured
    in current production or minimum values which the property does not fall below.

    2 The manufacturers submittal shall clearly state:

    (a) the type of material, (whether a polyethylene, propylene or other)


    (b) its structure whether (a monofilament, multifilament or other)
    (c) the element of manufacture by one or combination of the following processes:
    (i) Heat bonding.
    (ii) Chemical resin bonding
    (iii) Mechanical bonding.

    l .
    .l.
    3 If the Contractor wishes to propose a material that has been tested to alternative standards,
    the Contractor shall submit correlation tests showing the comparable values of the two test

    rw
    methods. These test results shall be comprehensive giving full details of the sample
    conditioning, preparation, method of test and criteria for assessment.

    4 ta
    The manufacturer shall submit comprehensive information of previous applications of the
    qa
    material in similar conditions and environments. This information shall include the project
    name, contract details, type/grade of material used, quantity of material used, name of the
    contract, client, consultant, and main contractor.
    as

    18.1.4 Quality Assurance


    se

    1 The geotextile shall be supplied by a manufacturer who is certified to the ISO 9001. The
    er

    Contractor shall submit to the Engineer a copy of the ISO 9001 certificate that clearly states
    the scope of the certification.
    ov

    2 The geotextile shall be supplied by a manufacturer who provides technical assistance on the
    o

    suitability for the application and installation for the material. For the initial use of the material
    it

    on site, the Contractor shall arrange for the technical representative of the manufacturer to
    et

    be present to demonstrate the correct use of the material.


    m

    3 Where feasible the jointing of geosynthetics shall be as prefabricated joints manufactured


    under factory controlled conditions. Joints made during the execution of the work shall be
    kept to a minimum.

    4 Joints shall be tested by the same test methods used for the main material.

    5 All joints used in permanent structures designed to carry loads shall be tested in accordance
    with BS EN ISO 10319 Part 1 or BS EN ISO 10321.

    6 In situations where relatively small tensions are developed and, if permitted by the Engineer
    overlapping joints may be used. These joints shall not be used in the primary tensile direction
    of reinforced soil structures but can be in secondary tensile directions only.

    7 Joints where geotextiles are sewn together shall be with one of the methods showing in
    figure 5 of BS8006. These joints shall meet the performance characteristics shown in Table
    8 BS8006.
    QCS 2014 Section 06: Road Works Page 4
    Part 18: Geosynthetics

    8 Prior to delivery of the material to site the Contractor shall submit a sample of a sawn joint.

    9 Bodkin joints shall have sufficient cross sectional area and strength to avoid excessive
    deformation. A bodkin joint shall not be so large so as to distort the material causing stress
    concentrations, bodkin joints shall be pretensioned prior to loading to reduce joint
    displacement as the components lock together.

    10 Any cuts, tears, splits and perforations to geosynthetics during installation shall be made
    good. The method of remedial work shall be prepared and proposed by the Contractor for
    approval by the Engineer.

    11 The geosynthetics shall be suitable for use in the ambient soil temperature in the State of
    Qatar.

    12 Geosynthetics that are able to ravel shall be heat treated or bonded with an adhesive tape at

    l .
    the cut. The proposed method of sealing the edges of geotextiles shall be proposed by the

    .l.
    Contractor and shall fully identify the geotextile material, type of scene, stitch configuration,

    rw
    stitch density, sowing thread and sowing machine to be used.

    18.1.5 Guarantees and Warranties

    1 ta
    The Contractor shall submit a ten-year guarantee for the geotextile material and the
    qa
    workmanship. The guarantee shall be worded to reflect the required performance of the
    material and shall be approved by the Engineer.
    as

    18.2 REQUIREMENTS FOR GEOTEXTILES


    se

    18.2.1 General Requirements


    er

    1 All geotextiles shall be supplied in manageable roll or unit sizes and shall be robust enough
    ov

    to withstand handling and any treatment received during the installation process.

    2 The geotextile shall comply with the minimum properties for geotextile serviceability in Table
    o

    18.1 below. The Engineer will direct as to the category that the geotextile shall meet; i.e., very
    it

    high, high, moderate or low.


    et

    Table 18.1
    m

    Minimum Properties for Geotextile Service Ability

    Very
    Property High Moderate Low
    High

    Grab Strength ASTM D 5034 1200 800 600 400


    Puncture Strength Modified ASTM D-751/3787, N 500 340 180 135
    Burst Strength 3.0 2.0 1.5 1.0
    Trapezoidal Tear ASTM D-4533 340 225 180 135

    These are the minimum required values below which no test result on production material
    should fall.
    QCS 2014 Section 06: Road Works Page 5
    Part 18: Geosynthetics

    3 The Engineer may require the Contractor to carry out tests to different standards, in addition
    to the test methods designated above or in the following clauses:

    (a) the manufacturers recommendations concerning the installation process shall be


    strictly adhered to
    (b) all geotextiles shall be suitable for use in the environmental conditions in the State of
    Qatar
    (c) geotextiles shall be resistant to deterioration on degradation from acids alkalis,
    bacteria, brackish or saline water. The manufacturer shall submit comprehensive
    results of tests carried out to demonstrate the durability of the materials under such
    conditions. These tests shall involve checking the strength properties of the material
    before and after prolonged exposure to typical groundwater conditions in the State of
    Qatar

    .
    (d) all geotextiles shall be protected from direct sunlight by storing inside the building or

    l
    .l.
    covering with heavy tarpaulins. Geotextiles shall not be exposed to direct sunlight for
    a duration longer than 48 h

    rw
    (e) joints in Geotextiles shall be sewn where load transfer is required

    18.2.2 Drainage Applications ta


    qa
    1 Geotextiles for drainage applications shall be needled polypropylene and meet the
    performance specifications given in Table 18.2. The performance shall be assessed based
    as

    on regular tests on the production material. Unless a permitted variation is stated in Table
    18.2, the mean test values shall meet the values in the Table.
    se
    er

    Table 18.2
    ov

    Performance Specifications for Geotextiles for Drainage Applications


    o

    International Classification
    1 2 3 4
    it

    According to CBR Test


    et
    m

    CBR test (DIN 54307)

    mean value 10 % 780 1335 2695 4400


    mean value minus standard deviation
    10 % 700 1200 2450

    deformation % 30 50 60 65

    Tensile strength (ASTM D 5035)

    longitudinal direction kN/m 10 % 3 7 12 25

    longitudinal direction kN/m 10 % 3 8 14 35


    QCS 2014 Section 06: Road Works Page 6
    Part 18: Geosynthetics

    International Classification
    1 2 3 4
    According to CBR Test

    elongation at rupture % 35/45 50/60 45/55 90/65

    Fall cone test hole diameter BS EN ISO


    50 32 18 6.5
    10319

    Water permeability at 2 kPa mech. load


    -2 -2 -2 -2
    permeability coefficient cm/s 9 x 10 8 x 10 13 x 10 15 x 10

    .
    at 10 cm water column l/secm 30 %
    2
    150 90 80 45

    l
    .l.
    rw
    Pore size (unvibrated)

    d 50% 80
    ta 60 45 30
    qa
    d 90% 110 85 65 40
    as

    2
    Weight DIN 53854 g/m 100 140 250 500
    se
    er

    Thickness DIN 53855 mm 0.6 0.95 1.5 3.4


    ov
    o

    2 The manufacturer shall clearly identify to which international classification category the
    it

    geotextile conforms according to the CBR test.


    et

    3 The pore size of the geotextile shall be small enough to prevent the significant loss of soil
    m

    particles from the retained soil, yet have adequate permeability to allow water transmission
    normal to the plain of the geotextile.

    4 The manufacturer shall submit test results that demonstrate the ability of the geotextile to
    avoid clogging during water flow due to fine particles. Test results for the US Corps of
    Engineers gradient ratio test or similar type of test shall be submitted. The test shall be
    carried out using soil of the type where the geotextile is to be installed. Gradient ratios
    derived from the test shall be less than 3.

    18.2.3 Earthworks Applications

    1 Geotextiles for earthworks reinforcement or base use shall be woven polyester multi-filament
    or multi-filament fabrics with a high rupture strength and low axial strain. The geotextile shall
    have an adequate high tensile strength in all directions to resist loading imposed by uneven
    filling.
    QCS 2014 Section 06: Road Works Page 7
    Part 18: Geosynthetics

    2 The geotextile shall possess the strength for the required design life with minimal increase in
    strain over time. The average geotextile strain shall be limited to 5 %.

    3 Where installed between a sub-base and the underlying soil, the geotextile shall prevent the
    granular material being pressed into the subsoil and also prevent an intrusion of fines from
    subgrade into the sub-base.

    4 The water permeability of the geotextile shall prevent build up of water pressure under the
    separation layer. The short- and long-term permeability of the geotextile must be equal to or
    greater than that of the subsoil. The geotextile must not become blocked.

    5 The geotextile shall possess high puncture resistance and a high tearing resistance.

    6 Where used as base stabilisation for embankments the type of construction equipment used

    .
    for spreading and compacting initial fill layers shall be suitable so as to avoid damage to the

    l
    .l.
    geotextile. The initial layer of fill placed on the geotextile shall be free from sharp angular or
    pointed material that may puncture the geotextile.

    rw
    7 Trucks shall not be permitted to drive over the geotextile. The laying of the material shall be
    co-ordinated to ensure that trucks do not damage the material.
    ta
    qa
    18.3 GEOGRIDS

    18.3.1 General Requirements for Geogrids


    as

    1 The geogrid shall be identified as either uniaxial for single dimension loading or biaxial for
    se

    two dimensional loading.


    er

    2 The design of all geotextiles or geogrid applications shall be based on an appropriate in soil
    temperature for the state of Qatar.
    ov

    3 The type of geogrid to be used shall be as shown on the drawings or as described elsewhere
    in the contract documents.
    it o

    4 The type of polymer used in the manufacture of the geogrid shall be clearly stated.
    et
    m

    5 The design shall take into account any possible damage to the material during site
    installation and a factor shall be introduced into the design.

    6 Prior to installing the geosynthetic the Contractor shall prepare a construction trial outside of
    the permanent works. The construction trial shall utilise similar ground conditions from
    materials and other factors as the permanent works.

    7 If directed by the Engineer the Contractor shall arrange for geotechnical investigation to be
    carried out in the area where the geosynthetics are to be installed. The range and details of
    the tests and investigations to be performed shall be directed by the Engineer.
    QCS 2014 Section 06: Road Works Page 8
    Part 18: Geosynthetics

    18.3.2 Material Requirements for Geogrids

    1 Geogrids shall be manufactured from a continuous sheet of polyethylene or polypropylene


    which is punched with a regular pattern of holes. The sheet shall be heated and stretched so
    that randomly orientated long chain molecules are drawn into an order and align state to
    increase tensile strength and tensile stiffness.

    2 The bars or ribs of the geogrid transverse to the direction of primary loading shall provide a
    series of bearing points or anchors such that stress is transferred to the grid by surface
    friction and also interaction.

    3 The ribs of the geogrid in both the longitudinal and transverse direction shall be
    manufactured to a near vertical face to provide good bearing surface for interlocking fill
    particles.

    . l
    4 Geogrids shall be resistant to deterioration by aqueous solutions of acids, alkalis and salts,

    .l.
    petrol, and diesel fuel.

    rw
    5 Geogrids shall not be susceptible to hydrolysis, environmental stress, cracking or micro
    biological attack.

    6 ta
    The manufacturer shall supply test results for load against strain for the material identifying
    qa
    all test conditions including strain rate and temperature of materials tested and test method.
    as

    7 The Contractor shall submit full technical details of the geogrid proposed for use in the works.
    These details shall include the following:
    se

    (a) grid dimensions


    er

    (b) thickness of longitudinal and transverse ribs


    (c) strength of the material determined as stress strain, at strains of 2 and 5% both
    ov

    (d) transverse and longitudinally in accordance with BS EN ISO 10319


    (e) weight in kilograms per metre squared for material
    o

    (f) the supplied roll of dimensions


    it
    et

    (g) the minimum amount of carbon black tested in accordance with BS 2782 Part 4
    (h)
    m

    the approximate peak strain , expressed as a percentage


    (i) the creep of the material under load determined in accordance with BS EN ISO 10319
    for strain shall not exceed 10%
    (j) the cross sectional shape of the ribs and of the rib joints.

    All test results shall be expressed as a lower 95% conference limit in accordance with ISO
    2602.
    8 The Contractor shall submit test results for the durability of geogrids. Tests shall be in
    accordance with PD 6533, - Guide To Methods for Assessing the Durability of Geotextiles.

    9 The Contractor shall submit laboratory test results for prolonged exposure tests at similar
    temperatures.

    10 For each batch or delivery of the geosynthetic the Contractor shall submit the production
    quality control test results shall be clearly related to batches delivered to site.
    QCS 2014 Section 06: Road Works Page 9
    Part 18: Geosynthetics

    18.3.3 Installation of Geogrids

    1 Prior to placing geogrids the Contractor shall prepare a detailed method statement for the
    sequence of operations.

    2 The methods employed shall ensure that the geosynthetic does not suffer deterioration
    during placing and that any joints are formed effectively.

    3 The handling and placement and installation of geogrids shall be carried out strictly in
    accordance with the manufacturers recommendations.

    4 Where the geogrid has been protected by a wrapping resistant to ultraviolet lights attack no
    further protection against sunlight is necessary.

    5 For geogrids, jointing shall be by a bodkin whereby two overlapping sections are coupled

    l .
    together using a bar passed through the aperture of the grid. Joints shall be formed at the

    .l.
    highest mechanical and durability efficiency possible.

    rw
    6 If necessary the Contractor shall construct a temporary access road to the site location at a
    convenient location close to the works, the Contractor shall prepare a clean working platform

    ta
    in storage area to accommodate geosynthetic materials.
    qa
    7 The geogrid shall extend across the full width of the embankment or area being treated in
    one continuous piece and no part bits of rolls shall be used. This shall be accommodated by
    as

    increasing the lap lengths.

    8 Prior to installation of the geogrid , the site shall be cleared in accordance with part 2 of this
    se

    specification
    er

    9 Before placing geogrid any abrupt changes in ground profile should be levelled.
    ov

    10 Any regulating layer of fill placed shall not impair the vertical hydraulic conductivity of the
    natural ground.
    it o

    11 Geogrids supplied in rolls shall be supported at a minimum of 2 points to prevent excessive


    et

    bending unless a central steel tube is used for support.


    m

    12 Site handling of geogrids shall ensure that damage to the product such as surface abrasions,
    splitting, notching or tearing is prevented.

    13 The installation of the geogrid shall be consistent with the direction of major stress.

    END OF PART
    QCS 2014 Section 06: Road Works Page 1
    Part 19: Miscellaneous

    19 MISCELLANEOUS ........................................................................................ 2

    19.1 STONE PITCHING ........................................................................................ 2


    19.1.1 Scope 2
    19.1.2 References 2
    19.1.3 Submittals 2
    19.1.4 Materials 2
    19.1.5 Installation 2
    19.2 GABIONS & PROTECTION MATTRESS ...................................................... 3
    19.2.1 Scope 3
    19.2.2 References 3
    19.2.3 General Requirements 4

    .
    19.2.4 Specific Requirements for Gabions 5

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    19.2.5 Specific Requirements for Protection Mattress 5

    rw
    19.3 BOLLARDS .................................................................................................... 6
    19.3.1 Scope 6
    19.3.2
    19.3.3
    References
    Concrete Bollards ta 6
    6
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    19.3.4 Steel Bollards 7
    19.4 RUMBLE STRIPS .......................................................................................... 7
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    19.4.1 Scope 7
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    19.4.2 Quality Assurance 7


    19.4.3 Construction 7
    er

    19.5 SPEED CONTROL HUMPS .......................................................................... 8


    ov

    19.5.1 Scope 8
    19.5.2 General 8
    o

    19.5.3 Construction of Speed Humps 9


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    et
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    QCS 2014 Section 06: Road Works Page 2
    Part 19: Miscellaneous

    19 MISCELLANEOUS
    19.1 STONE PITCHING

    19.1.1 Scope

    1 Stone pitching slope treatment shall consist of the placement and grouting of stone pitching
    on slopes at the designated locations or at the locations directed by the Engineer to the
    designated lines, grades, thickness and cross-sections or as directed by the Engineer.

    2 Related Sections and Parts


    This Section
    Part 3 Earthworks

    .
    19.1.2 References

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    1 The following standards are referred to in this Subpart:

    rw
    AASHTO T96 .............Resistance to Abrasion by Use of the Los Angeles Machine

    ta
    BS 812 Part 2 .............Testing Aggregates - physical properties
    qa
    BS 1881......................Methods of testing concrete

    19.1.3 Submittals
    as

    1 Samples of the stone to be used shall be submitted to and approved by the Engineer before
    se

    any stone is placed. These samples shall be kept on site and used for reference purposes for
    the quality control of delivered material during the work.
    er

    19.1.4 Materials
    ov

    1 Stone for pitching shall be hard, sound, durable, erosion resistant rock or cobbles.
    o

    2 The nominal weight of the stones shall be between 3 to 4 kg (corresponding to a size of


    it

    about 240mm x 140mm x 100mm). The maximum weight of the stones shall be between 32
    et

    kg (corresponding to a size of about 420mm x 230mm x 200mm).


    m

    3 Tests for specific gravity and absorption, shall be determined in accordance with BS 812 part
    2 Testing Aggregates - physical properties. The minimum apparent specific gravity shall be
    2.5 and the maximum absorption shall be 3 %.

    4 The stone shall not have an abrasion loss greater than 45 % when subjected to five hundred
    (500) revolutions in a Los Angeles Abrasion Machine in accordance with AASHTO T96.

    5 The size and shape of the stones shall be such to allow for proper placement. The widths of
    the stone shall be not less than one and one-half times their respective thickness and lengths
    of not less than two times their respective widths.

    19.1.5 Installation

    1 The bed upon which the stones are to be placed shall be excavated to the designated grades
    and lines or as directed by the Engineer.
    QCS 2014 Section 06: Road Works Page 3
    Part 19: Miscellaneous

    2 Prior to commencing any stone pitching operations the Contractor shall prepare a trial laying
    of not less than 2 m by 2 m using the materials and methods proposed for the work. The trial
    laying shall establish the aesthetic appearance of the work and shall be used for comparison
    purposes for acceptance of the final work.

    3 A footing trench shall be excavated along the toe of the slope as designated or as directed by
    the Engineer. All footing trenches and excavations shall be approved by the Engineer before
    placement of stones or concrete.

    4 Subgrade or base shall be firm and well compacted and approved by the Engineer. A 50 mm
    thick layer of mortar shall be laid on the subgrade as bedding for the stones.

    5 Stones shall be placed so as to provide a minimum number of voids; larger stones shall be
    placed in the footing trench and on the outside surface of the slope. The flattest face of the
    stone shall be laid uppermost parallel to the slope. Spaces between larger stones shall be
    filled with the smaller stones.

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    6 The surfaces of the stone shall be cleaned of adhering dirt and clay and shall be moistened
    immediately prior to grouting.

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    7 The space between stones of stone pitching shall be filled with mortar consisting of one part
    Portland cement and three parts of fine aggregate, and one-fifth part of hydrated lime with

    ta
    sufficient water to produce a workable mix as approved by the Engineer.
    qa
    8 Sand and cement shall comply with the requirements of Section 5. The compressive strength
    of the mortar shall not be less than 15 MPa when tested in accordance with BS 1881 Part
    108.
    as

    9 Immediately after placing, the mortar shall be spaded and rodded into place with suitable
    se

    spades, trowels or other approved method. All the voids between stones shall be completely
    filled.
    er

    10 The exposed surface of the rocks shall project not less than 1 cm and not more than 4 cm
    ov

    above the mortar surface. The mortared stone pitching shall be cured by an approved
    method for a minimum period of four days. Immediately after the expiration of the curing
    period, the exposed surfaces shall be cleared of all curing mediums.
    it o

    11 Joints will be provided at a maximum interval of 12 m. Joints shall comprise a gap in the
    et

    stone pitching of 15 mm. The method of forming the gap shall be to the approval of the
    Engineer.
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    19.2 GABIONS & PROTECTION MATTRESS

    19.2.1 Scope

    1 This work shall consist of supplying, building and placing of stone-filled gabions or protection
    mattress as slope or watercourse channel protection.

    2 Related Sections and Parts


    This Section
    Part 3 Earthworks
    19.2.2 References

    1 The following standards are referred to in this Subpart:


    BS EN 10244..............Testing zinc coatings on steel wire and for quality requirements
    QCS 2014 Section 06: Road Works Page 4
    Part 19: Miscellaneous

    BS EN ISO 1461.........Hot dip galvanised coatings on iron and steel articles


    BS 1052......................Mild steel wire for general engineering purposes
    BS 1722 Part 16 .........Organic powder coating to be used as a plastics finish to components
    and mesh

    ASTM G152 and G153-----Practice for Operating Light-Exposure Apparatus (Carbon-Arc


    Type) With and Without Water for Exposure of Nonmetallic Materials.

    19.2.3 General Requirements

    1 Gabion boxes and protection mattress shall be made of a hexagonal woven mesh of double
    twisted hot dip galvanised steel wire. The nominal mesh size shall be 80mm x 100mm.
    Details of type of mesh proposed for use shall be submitted to the Engineer for approval.

    2 Wire shall be coated with a minimum thickness of 0.55 mm of dark green or black PVC

    l .
    complying with BS 1722 Part 16 Organic powder coating to be used as a plastics finish to

    .l.
    components & mesh.

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    3 Wire shall be capable of resisting the effects of immersion in sea water, exposure to
    ultraviolet light and abrasion, when tested for a period not less than 3000 h in accordance
    with ASTM G152 and G153.
    ta
    qa
    4 The cages of gabion panels and protection mattress panels shall be selvedged to prevent
    unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of
    not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for
    as

    the wire core. Wire for selvedges and lacing shall otherwise comply with the same
    specification for the wire used in the mesh.
    se

    5 Non-metallic material such as extruded polypropylene for gabion boxes may be proposed, for
    the Engineer's approval. Samples and manufacturer's certificates shall accompany the
    er

    proposal. The Contractor shall demonstrate that non-metallic materials are suitable for use in
    the climatic conditions of Qatar.
    ov

    6 Gabion and protection mattress dimensions shall be as designated. A tolerance of 5 % on


    width and height, and 3 % on length shall be allowed.
    it o

    7 Gabions and protection mattress shall have diaphragms at 1 m centres.


    et
    m

    8 Wire used in the fabrication of the gabion and protection mattress shall be mild steel to BS
    1052 having an average tensile strength, before coating, of 380 to 500 MPa. The core wire
    diameter shall be 3.0 mm before galvanising. Galvanising shall comply with BS EN 10244.

    9 Non-metallic gabion and protection mattress cages of proprietary type shall be constructed
    according to the manufacturer's instructions.

    10 All the fixing and binding wires shall be coated with PVC layer complying with BS 1722 Part
    16.

    11 All Gabions and mattresses shall be laid over a layer of geotextile membrane Grade 3000 at
    all times.
    QCS 2014 Section 06: Road Works Page 5
    Part 19: Miscellaneous

    19.2.4 Specific Requirements for Gabions

    1 Stones for gabion filling shall be hard, sound, durable and highly resistant to erosion. The
    stone size distribution in each individual box shall be as shown in Table 16.1:
    Table 16.1
    Stone Size Distribution of Gabions

    Size of Stones mm % of Total (by number)

    80 - 125 7 maximum

    125 - 200 88 maximum

    200 - 250 5 maximum

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    2 Gabions shall be placed and built to the designated lines, levels and patterns on a prepared

    rw
    horizontal foundation surface, excavated as required and compacted as directed by the
    Engineer.

    3
    ta
    Gabion cages shall be securely wired together at comers and cages, and where there is
    more than one course of gabions, the upper course cages shall be laced to the lower course.
    qa
    Before filling, the cage shall be in its permanent position and laced to adjoining previously
    filled cages.
    as

    4 Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
    voids. Tie wires shall be fixed inside the compartments and the units tensioned in
    se

    accordance with the manufacturer's instructions.


    er

    5 The cages shall be overfilled with stones to allow for subsequent settlement and the lid laced
    down with binding wire to the top of each of the four sides and to the top of the diaphragm
    ov

    panels.

    19.2.5 Specific Requirements for Protection Mattress


    it o

    1 The material shall be supplied as a large sheet with partition panels at 1 m centres to form a
    et

    cellular structure with the sheet turned up to form the sides. A separate sheet shall form the
    lid.
    m

    2 The cages of protection mattress panels shall be selvedged to prevent unravelling of the
    mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0
    mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core.
    Wire for selvedges and lacing shall otherwise comply with the same specification for the wire
    used in the mesh.

    3 Stones for protection mattress filling shall be hard, sound, durable and highly resistant to
    erosion.

    4 The stone size distribution in each individual box shall be dependent on the design thickness
    of the mattress as shown on the contract drawings.

    5 The protection mattress shall be a special type of rectangular gabion with a large plan area to
    thickness ratio that is divided into compartments by partition panels fixed to the base.
    QCS 2014 Section 06: Road Works Page 6
    Part 19: Miscellaneous

    6 The thickness of the protection mattress, the installation slope and the panel size shall be as
    designated. The Contractor may elect to use a manufacturers standard size of mattress that
    is thicker than that designated.

    7 Protection mattress shall be placed and built to the designated lines, levels and patterns on a
    prepared foundation surface, excavated as required and compacted as directed by the
    Engineer.

    8 Protection mattress cages shall be securely wired together at comers and cages. Before
    filling, the cage shall be in its permanent position and laced to adjoining previously filled
    cages. Several assembled units should be placed in position and wired together at their
    edges with the wire passed continuously through each mesh in turn with a double turn at
    every second mesh.

    9 Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
    voids. Tie wires shall be fixed inside the compartments and the units tensioned in

    .
    accordance with the manufacturer's instructions.

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    19.3 BOLLARDS

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    19.3.1 Scope

    1
    ta
    Short metal or precast concrete bollards for traffic control in roads or pedestrian areas.
    qa
    2 Related Sections
    Section 5 Concrete
    as

    19.3.2 References
    se

    1 The following standard is referred to in this Part:


    er

    BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles.
    ov

    19.3.3 Concrete Bollards

    1 The use of cast in-situ concrete bollards will not be permitted.


    it o

    2 Precast concrete bollards shall be constructed with the dimensions and details shown in the
    et

    drawings. The surface finish and colour of the bollards shall be as shown in the drawings, in
    the Project Specification, per the designated details or as directed by the Engineer.
    m

    3 All concrete and steel materials and procedures for the precast concrete bollards shall
    comply with the requirements of Section 5.

    4 The minimum grade of concrete for bollards shall be C40. Bollards shall be constructed using
    OPC cement to BS EN 197-1.

    5 The minimum cover to all embedded steel items in the bollards shall be 50mm with a
    tolerance of -0 mm and + 10 mm.

    6 Where precast concrete bollards are specified the Contractor shall design the bollards such
    that the durability is ensured for a period of ten years. The Contractor shall submit a
    performance guarantee for the bollards for a period of ten years. The guarantee shall provide
    for the replacement of the bollard in the event of any deterioration due to exposure to the
    elements.
    QCS 2014 Section 06: Road Works Page 7
    Part 19: Miscellaneous

    7 The supplier shall verify this by a design submission covering the concrete mix design,
    special admixtures additives, cover to reinforcement type of reinforcement and protective
    coating. The engineer shall approve the material and design for the bollard based on the
    particular exposure of the location proposed for use.

    8 Prior to production of the precast bollards the Contractor shall cast a trial bollard for approval
    by the Engineer.

    19.3.4 Steel Bollards

    1 Metal bollards shall be constructed of steel tube with the dimensions, details, wall thickness
    and height shown on the drawings or provided in the Project Specification.

    2 The top of the bollard shall be ground free of any rough edges and fitted with a tight durable
    ultraviolet light resistant plastic top.

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    3 All metal parts shall be hot dipped galvanised to BS EN ISO 1461 after fabrication.

    rw
    4 All metal parts shall also be painted to the colours and pattern as shown on the drawings or
    directed by the engineer. The paint system shall be compatible with the hot dipped

    ta
    galvanising and shall provide a service free life for five years.
    qa
    5 Where designated, bollards shall be removable. This shall be achieved by casting a 4 mm
    thick PVC pipe sleeve into the pavement. The bollard shall be a tight fit into this sleeve. If so
    as

    designated or directed by the Engineer a locking facility shall be incorporated with the
    removable bollard.
    se

    19.4 RUMBLE STRIPS


    er

    19.4.1 Scope
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    1 Rumble strips to provide warning to drivers of vehicles that accidentally stray out of the
    o

    carriageway.
    it

    2 Related Parts
    et

    This Section
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    Part 5 Asphalt Works.


    19.4.2 Quality Assurance

    1 The Contractor shall arrange for a trial installation of a rumble strip to demonstrate the
    methods and equipment to be used. Approval to proceed with the construction of the rumble
    strips will only be permitted after the Engineer has approved this trial in writing.

    19.4.3 Construction

    1 Rumble strips shall comprise of shallow formed depressions in the wearing course of the
    road shoulders. The depth, plan size and layout of the rumble strips shall be as designated or
    as directed by the Engineer.

    2 Rumble strips shall be formed by one of the following methods:


    (a) cold planing
    QCS 2014 Section 06: Road Works Page 8
    Part 19: Miscellaneous

    (b) Removal shutter boards.


    3 Cold planing of indentations in the wearing course in the shoulder shall be carried out in
    accordance with the requirements of the cold planing of Part 5. Edges shall be square and
    true and free from any loose material.

    4 Rumble strips may also be formed by the use of removable shutter boards. The boards shall
    be rigidly located on the base or binder course prior to laying the wearing course. The
    method of fixing the strip shall be subject to the approval of the Engineer. The laying of the
    wearing course shall be carried out in accordance with the requirements of Part 5. Care shall
    be taken to ensure full compaction of material around the edges of the shutter boards. The
    shutter boards shall be carefully removed not earlier than three days after the laying and
    compaction of the asphalt.

    19.5 SPEED CONTROL HUMPS

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    19.5.1 Scope

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    1 Speed control humps to limit the speed of vehicles.

    2 Related Parts
    ta
    qa
    This Section
    Part 5 Asphalt Works.
    Part 9 Kerbs, Footways & Paved Areas.
    as

    19.5.2 General
    se

    1 Speed control humps shall only be installed at the locations designated on the project
    drawings or specified elsewhere within the contract documents.
    er

    2 All speed humps shall be identified by markings on the road surface. The layout of these road
    ov

    markings shall be as the Qatar traffic control manual or as shown on the project drawings or
    elsewhere in the contract documentation.
    it o

    3 The profile of the speed hump shall be as shown on the project drawings.
    et

    4 The profile shall represent a smooth gradual rise in elevation.


    m

    5 Speed humps shall be constructed of the same asphalt mix design as the asphalt wearing
    course.

    6 The use of prefabricated rubber section speed humps or steel checker plate filled with
    concrete speed humps is not permitted.

    7 Speed humps shall be designated as one of two types; for low speed pedestrian areas and
    for high speed roads. Low speed pedestrian areas speed humps shall comprise of a ramp
    within elevated section constructed of interlocking concrete paving blocks.
    QCS 2014 Section 06: Road Works Page 9
    Part 19: Miscellaneous

    19.5.3 Construction of Speed Humps

    1 The dimensions and construction details of speed hump shall be as shown on the drawings.

    2 Prior to installation of the speed hump the surface of the wearing course shall be scabbled or
    abraded to a rough irregular finish to ensure bond with the speed hump. Tack coat shall be
    applied at the base.

    3 Wearing course shall be hand laid for the speed hump. The wearing course shall be
    compacted and finished to a smooth profile.

    4 All the asphalt work for the speed hump shall comply with the relevant clauses in part 5 of the
    specification. The final profile speed hump shall comply to the profile on the drawings to
    within 6mm.

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    5 Heavy traffic or construction plant shall not be permitted to drive over speed humps until

    .l.
    7 days after the construction unless the engineer permits otherwise.

    rw
    END OF PART

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    QCS 2014 Section 06: Road Works Page 1
    Part 02: Site Clearance

    2 SITE CLEARANCE .................................................................................................. 2


    2.1 GENERAL ............................................................................................................... 2
    2.1.1 Scope of Work 2
    2.1.2 References 2
    2.1.3 Submittals 2
    2.2 PROTECTION TO EXISTING SERVICES AND INSTALLATIONS.......................... 3
    2.3 RECOVERY OF MATERIALS ................................................................................. 4
    2.4 CLEARING AND GRUBBING .................................................................................. 4
    2.5 REMOVAL OF STRUCTURES ................................................................................ 5
    2.6 REMOVAL OF STREET FURNITURE ..................................................................... 6
    2.7 REMOVAL OF FENCES .......................................................................................... 6

    .
    2.8 REMOVAL OF EXISTING PAVEMENTS ................................................................. 6

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    2.8.1 General Requirements 6

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    2.8.2 Cutting Back Pavement 6
    2.8.3 Stockpiling Asphalt Pavement 7
    2.8.4 Stockpile Site 7
    2.9 ta
    MEASURES FOR STATUTORY UNDERTAKERS .................................................. 8
    qa
    2.10 REMOVAL OR TREATMENT TO BURIED UTILITIES ............................................ 8
    2.10.1 General 8
    as

    2.10.2 Underground Storage Tanks 8


    2.10.3 Removal of Culverts 8
    se

    2.10.4 Abandoned Pipes and Culverts 9


    2.10.5 Total Removal of Pipelines 9
    er

    2.10.6 Grouting of Pipelines 9


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    2.10.7 Plugging of Pipelines 10


    2.10.8 Cut-off Walls and Capping Slabs 10
    2.10.9 Manholes and Access Shafts 10
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    2.10.10 Drainage Inlets and Gullies 10


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    et

    2.11 DISPOSAL OF MATERIALS.................................................................................. 10


    m
    QCS 2014 Section 06: Road Works Page 2
    Part 02: Site Clearance

    2 SITE CLEARANCE

    2.1 GENERAL

    2.1.1 Scope of Work

    1 This Part includes:

    (a) Excavating for, demolishing and removing wholly or in part and disposing of
    designated redundant pavements, fences, buildings, culverts, manholes, inlets, gullies,
    pipelines or any other obstructions.
    (b) Associated earthworks to uncover facilities to be demolished, removed or recovered
    and to backfill and compact all trenches, holes, pits or excavations resultant from
    demolition, removal and recovery works.

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    (c) Recovering designated materials for storage and reuse.

    rw
    (d) Removing and, where required, recovery of designated water, gas and sewage
    pipelines and fittings and of underground cables.
    (e) Disposal of materials not recovered.
    (f) ta
    Removal of vegetation and surface boulders and rocks.
    qa
    2 Related Parts and Sections are as follows:
    as

    This Section: Part 3 Earthworks


    Part 5 Asphalt Works
    se

    Part 11 Works in Relation to Services


    er

    Section 2 Building Demolition


    Section 5 Concrete
    ov

    Section 8 Sewerage
    Section 12 Earthworks Related to Buildings
    o

    2.1.2 References
    it
    et

    1 The following standards are referred to in this Part:


    m

    BS 5228......................Code of practice for noise control on construction and demolition sites


    BS 6187......................Code of practice for demolition

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

    1 Where existing services are to remain and are in close proximity to the works the Contractor
    shall submit to the Engineer details of proposed measures to ensure that the existing
    services are kept in a safe and stable condition for the duration of the Works.

    2 Structures and installations to be dismantled or demolished shall be surveyed by the


    Contractor to ascertain exposed constructional dimensions and details. The Contractor shall
    prepare sketches of the structures and installations and submit these to the Engineer. This
    information shall be used by the Engineer to confirm the scope of the dismantling or
    demolition and confirm materials or equipment to be recovered.
    QCS 2014 Section 06: Road Works Page 3
    Part 02: Site Clearance

    3 The method of dismantling and demolition including the sequence of operations and any
    special procedural requirements shall be submitted to the Engineer for consideration not less
    than seven days before the work is due to begin. Demolition work shall be carried out in
    accordance with BS 6187, and the submittal shall include information demonstrating the
    Contractors proposed methods to attain compliance.

    4 Before any blasting operation the Contractor shall submit a detailed method statement for the
    work. Blasting work shall be carried out in accordance with The Guide for Civil Users of
    Explosives in Qatar, prepared by the former Ministry of Industry and Public Works. Approvals
    for blasting work shall be obtained as per the requirements of part 3 of the specification for
    rock excavation.

    5 The Contractor shall submit for approval his proposed method of grouting pipes to be
    abandoned.

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    6 Before commencing work on the construction of reinforced concrete cut-off walls and

    .l.
    reinforced concrete capping slabs the Contractor shall submit details for the Engineer's

    rw
    approval.

    2.2 PROTECTION TO EXISTING SERVICES AND INSTALLATIONS


    ta
    qa
    1 The Contractor shall conduct his operations in such a manner as to avoid hazards to
    persons, property and vehicles. After work is started on any structure, work on that structure
    shall be continued to completion promptly and expeditiously.
    as

    2 Services to unused installations shall be safely disconnected before demolition. Notification


    se

    of disconnection shall be given to the appropriate authorities.


    er

    3 Drains, manholes and gullies that are to remain shall be protected and kept clear of debris at
    all times. They shall be left clean and in working order.
    ov

    4 Details of any underground caverns, chambers, wells or voids discovered during the
    demolition operation shall be reported to the Engineer. Dangerous openings shall be
    o

    protected and illuminated.


    it
    et

    5 Precautions shall be taken to prevent leakage or formation of flammable, explosive,


    m

    unhealthy or environmentally hazardous gas or vapour.

    6 Pits, drains and manholes shall be checked before entry to ensure that the atmosphere is fit
    for respiration.

    7 The quantity of dust in the atmosphere shall be minimised by spraying the demolition works
    with water.

    8 The recommendations of BS 5228: Part 2 shall be followed in minimising noise and vibration.
    Silencing devices on plant shall be fitted where practicable and ear defenders shall be
    provided for site personnel where noisy machinery is used.

    9 The location of any survey stations shall be reported to the Engineer. The Engineer may
    require the Contractor to transfer existing survey stations to new locations and carry out a
    survey to verify the level and co-ordinates of the new survey stations.
    QCS 2014 Section 06: Road Works Page 4
    Part 02: Site Clearance

    10 All existing structures, paving, services, fittings, and other features which are not to be
    demolished, dismantled, removed or otherwise dealt with shall be protected from damage by
    a means approved by the Engineer.

    11 Adjacent structures shall be surveyed for movement, cracks or deformations before and after
    demolition. The definition of adjacent structures in this context will be decided by the
    Engineer dependent on the type of structure to be demolished and the method of demolition
    proposed by the Contractor and the risk of damaging adjacent property.

    12 A photographic record of the adjacent structures before and after demolition shall be taken.

    13 Where structures, paving, services, fittings or other features are damaged by the Contractor,
    they shall be made good to the satisfaction of the Engineer.

    2.3 RECOVERY OF MATERIALS

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    1 Where required the Contractor shall recover designated materials without undue damage,

    rw
    carry out any required cleaning and shall deliver the recovered materials to locations
    designated by the Engineer and unload and place them into storage.

    2
    ta
    Where on-site reuse is designated recovered materials shall be stored on site before their
    qa
    incorporation in the Works.

    3 Materials to be recovered shall be handled and stored in such a manner as to avoid any
    as

    damage which will impair their reinstallation and reuse. Where the absence of care results in
    damage, the Contractor shall repair the damage at his expense. If repairs are deemed to be
    se

    impracticable the Contractor shall provide replacements at his expense.


    er

    2.4 CLEARING AND GRUBBING


    ov

    1 The Contractor shall excavate and remove surface material such as debris, windblown sand,
    vegetation and any other unsuitable material in the areas and to the thickness instructed by
    the Engineer. Clearing and grubbing shall be restricted to removal of surface material and
    o

    debris and shall not include the excavation of natural ground unless directed by the Engineer.
    it
    et

    2 The removed material shall be loaded and transported to an approved dumping area.
    m

    3 All surface objects, trees, stumps, roots and other protruding obstructions not designated to
    remain shall be grubbed and cleared as follows:

    (a) In areas inside of the grading limits of cut and embankment areas, stumps and non
    perishable solid objects shall be cut off not less than one metre below the subgrade
    level in the area.
    (b) In areas outside of the grading limits of cut and embankment areas, stumps and non-
    perishable solid objects shall be cut off not less than 500 mm below finished ground
    level.
    (c) In areas to be rounded at the top of cut slopes, stumps shall be cut off flush with or
    below the surface of the final slope line.
    (d) Grubbing of pits and ditches will be required only to the depth necessitated by the
    proposed excavation within such areas.
    QCS 2014 Section 06: Road Works Page 5
    Part 02: Site Clearance

    (e) Except in areas to be excavated, stump holes and other holes from which obstructions
    are removed shall be backfilled with suitable material and compacted.
    (f) Where designated the Contractor shall carefully remove existing trees, plants or
    shrubs and carefully transport these to a location designated by the Engineer.

    2.5 REMOVAL OF STRUCTURES

    1 Unless otherwise directed the Contractor shall demolish and remove all buildings and
    structures within the limit of works limits together with all foundations and retaining walls,
    piers, partitions and columns down to a plane not less than one metre below the finished
    ground level or one metre below the subgrade level in the area.

    2 Upon receipt of notification by the Engineer, the Contractor shall take over all responsibility of
    the building or buildings then acquired and vacant and shall proceed with the demolition and

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    removal thereof.

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    3 All structures shall be neatly trimmed off and the reinforcement shall be cut or trimmed off

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    close to the concrete and made safe; basement floor slabs shall be broken into pieces;
    excess debris and other foundations, concrete floor slabs, sidewalks, driveways, signs,

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    sheds, garages, fences and other facilities shall be removed.
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    4 The Contractor shall arrange for the discontinuance and disconnection of any services to the
    structure or structures in accordance with the requirements of the agency concerned. The
    Contractor shall disconnect and properly seal in an approved manner any sewer outlets that
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    serve any structure he is to remove. The Contractor shall keep the Engineer informed of his
    plans for the performance of any work in connection with the sealing off of such outlets in
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    order that proper inspection can be provided at the time the work is performed.
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    5 Any additional small out-buildings or temporary structures even if not shown on the Drawings
    shall also be removed if directed by the Engineer.
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    6 Demolition and removal works shall be carried out mechanically or by hand as necessary in
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    such a manner as to cause no undue damage to the public, property, vehicles, pavements,
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    services and structures, and the Contractor shall provide temporary works for protection
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    when necessary, in accordance with any special requirements of the concerned authorities.
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    7 Blasting or other operations necessary for the demolition and/or removal of facilities which
    may damage new construction shall be completed before placing the new work, unless
    otherwise directed by the Engineer.

    8 In all cases the Contractor shall be responsible for all claims resulting from damage, of any
    nature, caused by carelessness or negligence on the part of the Contractor, his
    subcontractors or agents.

    9 Demolition or removal operations for any particular facilities shall not be started until written
    approval is obtained from the Engineer.

    10 Throughout the demolition period the Contractor shall provide and maintain sufficient and
    adequate temporary supports.
    QCS 2014 Section 06: Road Works Page 6
    Part 02: Site Clearance

    2.6 REMOVAL OF STREET FURNITURE

    1 Where designated, street furniture shall be recovered, cleaned and either delivered to and
    placed into storage at the stores of the designated authority or set aside for re-erection as
    part of the Works, or shall be removed and disposed of.

    2 The Works shall include the excavation, removal and disposal of all foundations.

    3 Before proceeding with the removal of any of the above installations the Contractor shall
    contact the relevant authority and obtain approval.

    4 The recovery of existing street lighting installations shall form part of the Works and shall be
    in accordance with the requirements of the Public Works Authority.

    2.7 REMOVAL OF FENCES

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    1 Where designated, fencing, including all support posts, gates, other accessories and

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    foundations shall be removed.

    2 The Contractor shall provide suitable termination's for remaining fencing whether inside or
    outside the right-of-way limits.
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    3 Unless otherwise directed all fencing, posts, gates and other accessories shall remain the
    property of the Employer and shall be carefully dismantled and delivered to and place into
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    storage on site or at the Employer's stores, the location of which shall be obtained from the
    Engineer. The supporting posts and supports shall be carefully cleaned of concrete, avoiding
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    damage to the posts.


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    4 Foundations and sections of fencing which are designated unsuitable for recovery by the
    Engineer shall be disposed of.
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    2.8 REMOVAL OF EXISTING PAVEMENTS


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    2.8.1 General Requirements


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    1 On sections of redundant existing roadway (and detours and diversions that are no longer
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    needed for traffic) the existing pavement structure together with all kerbs, kerb base and
    backing, sidewalk paving, edging or kerb to sidewalk paving including base and backing to
    same and other items shall be broken out and removed.

    2 Non-asphaltic pavement, kerbs, kerb base and backing, gutters and other associated debris
    shall be disposed of unless such items are designated for recovery.

    3 Where designated side drainage ditches and excavations shall be filled and the roadway
    rough graded to restore approximately the original contour of the ground or to produce
    natural, rounded slopes. After the rough grading is completed, the area of the old roadbed
    shall be scarified or ploughed to mix the remaining road material thoroughly with earth and
    then shall be harrowed and smoothed.

    2.8.2 Cutting Back Pavement

    1 The Contractor shall cut back all existing construction in such a manner to avoid damage to
    the construction which is to remain.
    QCS 2014 Section 06: Road Works Page 7
    Part 02: Site Clearance

    2 Any damage to the existing pavement and other work areas which are to remain shall be
    restored to the satisfaction of the Engineer.

    3 The details and dimensions of the cutting back of the existing pavement construction shall be
    as designated subject to a minimum benching step of 300 mm between each pavement
    course.

    4 The method of cutting back all existing construction shall be as approved by the Engineer.

    5 Once cut back all pavement edges shall be suitably protected against damage from
    construction traffic. Any such damage shall be made good before proceeding with pavement
    construction.

    2.8.3 Stockpiling Asphalt Pavement

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    1 During the recovery and stockpiling operations asphalt pavement containing soil or other

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    debris shall be kept separate from recovered pavement which does not contain soil or other

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    debris.

    2 Existing pavement designated for recovery shall be removed and stockpiled by methods

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    which will minimise losses and prevent it being contaminated with other materials. Especially,
    the Contractor shall ensure that the material is reasonably free of soil and other matter when
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    it is stockpiled.
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    2.8.4 Stockpile Site


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    1 The Engineer may direct that removed asphalt or concrete pavement is stockpiled for
    possible future use and the Contractor will transport all removed asphalt or concrete
    pavement to the designated stockpile location.
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    2 The Contractor shall inform the Engineer at least seven (7) days before he is ready to
    commence stockpiling operations and obtain written approval from the Engineer.
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    3 If not previously protected, the Contractor shall provide a protective enclosure around the
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    stockpile site to prevent unauthorised dumping by other Contractors and ensure that material
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    is not removed without authorisation. The protective enclosure around the stockpile site shall
    include a suitable lockable gate for entry.
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    4 The Contractor shall assure responsibility for maintenance of the stockpile site during the
    time he is depositing and removing material from the stockpile.

    5 Maintenance responsibility shall include but not be limited to:

    (a) Furnishing plant when directed by the Engineer to spread the material and shape the
    stockpile as successive loads of salvaged material are delivered.
    (b) Ensuring by whatever means required that no unauthorised dumping is allowed.
    (c) Consolidating and reshaping of stockpile from time to time and when final operations
    are complete.

    6 When directed by the Engineer the Contractor shall permit other contractors access to the
    stockpile site to deliver or remove materials.
    QCS 2014 Section 06: Road Works Page 8
    Part 02: Site Clearance

    2.9 MEASURES FOR STATUTORY UNDERTAKERS

    1 The Contractor shall take all measures required by any statutory undertaker, the
    management of other publicly owned services, or owners of privately owned services or
    supplies, for disconnection and proper sealing off of all redundant drains, services and
    supplies.

    2 The Contractor shall observe and comply with all the safety regulations that are in force for
    work associated with various services.

    3 Before commencing work on the removal or treatment to any utilities the Contractor shall
    contact the statutory undertakers and obtain their written approval.

    4 The removal of overhead power lines shall be carried out by the QGEWC or by a specialist
    contractor approved by the QGEWC.

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    2.10 REMOVAL OR TREATMENT TO BURIED UTILITIES

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    2.10.1 General

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    Designated existing underground storage tanks, culverts, box culverts, pipelines, pipes,
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    manholes, inlets, gullies and similar facilities for drainage or other designated utilities shall be
    totally or partially demolished as designated, all debris removed, the facility thoroughly
    cleaned out and the resultant void backfilled with suitable material (as defined in Section 6
    as

    Clause 3.3) and compacted.


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    2 Underground utilities, pits, chambers, cesspools and similar facilities shall be demolished to a
    depth of one metre below the finished subgrade level in the area, and shall be properly
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    cleaned out to full depth and backfilled with approved compacted materials.
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    3 Where designated, manhole and access shaft covers and frames and drainage inlet covers
    and frames shall be carefully removed, cleaned and transported to and placed into storage at
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    designated storage areas.


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    4 Materials not recovered for reuse shall be disposed of.


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    2.10.2 Underground Storage Tanks

    1 Existing underground storage tanks on the site or under structures designated for removal
    shall be removed and disposed of by the Contractor. The Contractor shall take all necessary
    precautions during the removal and disposal of any fluid within the tanks and of the tanks
    themselves.

    2.10.3 Removal of Culverts

    1 Where the total demolition of a culvert is designated the culvert top slab, walls, base slab and
    all manhole shafts, shall be broken out and all debris removed and disposed of.

    2 Where the partial demolition of the culvert is designated the top slab of the culvert shall be
    removed together with all manhole shafts. The side walls shall be broken out to the
    designated level or to a minimum of one metre below the subgrade level or the finished
    ground level in the area. The walls shall he neatly trimmed off and the reinforcement shall be
    cut or burned off close to the concrete.
    QCS 2014 Section 06: Road Works Page 9
    Part 02: Site Clearance

    2.10.4 Abandoned Pipes and Culverts

    1 Pipes and culverts no longer required which are designated to be abandoned in place shall
    either be filled with grout or concrete, as designated by the Engineer.

    2 All ends of abandoned pipes with a nominal diameter greater than 100 mm and less than 600
    mm and all ends of abandoned culverts with a cross-sectional area of 1.0 m2 or less shall be
    plugged by either mass concrete or a reinforced blockwork wall.

    3 All ends of abandoned pipes with a nominal diameter of 600 mm or greater and all ends of
    abandoned culverts with a cross-sectional area greater than 1.0 m2 shall be provided with a
    cut-off wall as designated.

    2.10.5 Total Removal of Pipelines

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    1 Where designated, pipelines, manholes and fittings together with any plain or reinforced
    concrete bed, haunch or surround shall be broken out, removed and disposed of.

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    2 Designated pipes and ring fittings to be reused shall be recovered in such a way as to leave
    them undamaged and suitable for reuse.
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    3 The method of taking apart the pipes and fittings shall be agreed with the Engineer before the
    start of the work.
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    4 Materials damaged in the process of recovery shall be repaired by the Contractor.


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    5 The pipes and fittings recovered shall have all extraneous material including concrete
    surround carefully removed, they shall then be thoroughly cleaned and delivered to the
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    designated storage area and placed into storage.


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    2.10.6 Grouting of Pipelines

    1 Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he


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    completely filled with a sand-cement grout.


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    2 The cement, fine aggregate and water used for the grout shall comply with the requirements
    of section 5 of the Qatar Construction Specification. The sand used for the grout shall be a
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    fine graded rounded sand that produces a free flowing grout.

    3 The grout shall comprise of one part cement to two parts fine aggregate with enough water to
    produce a free flowing and pumpable mix. The use of admixtures to improve the flow and
    setting characteristics of the grout will be permitted subject to the prior approval of the
    Engineer.

    4 Each end of the pipe shall be plugged. No grouting shall commence until the Engineer's
    approval has been obtained.

    5 The Contractor may propose alternative methods of filling the pipe for the approval of the
    Engineer. The Engineer shall retain the right to designate certain pipes that shall be filled with
    grout irrespective of any approval to alternative methods of filling.
    QCS 2014 Section 06: Road Works Page 10
    Part 02: Site Clearance

    2.10.7 Plugging of Pipelines

    1 Designated pipes shall be plugged by mass concrete as per section 5 of Qatar Construction
    Specification to a minimum of one metre lateral extent into the pipe.

    2 The method of constructing the plug to ensure a solid watertight seal shall be approved by
    the Engineer.

    2.10.8 Cut-off Walls and Capping Slabs

    1 Where designated the Contractor shall construct a reinforced blockwork cut-off wall to box
    culverts and pipelines and a reinforced concrete capping slab to manholes and access
    shafts.

    2 Reinforced blockwork cut-off walls shall extend beyond the edges of the pipe and shall be

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    founded on a mass concrete of grade 20 as per section 5 of Qatar Construction

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    Specification.

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    2.10.9 Manholes and Access Shafts

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    Unless otherwise designated, manholes and access shafts shall be broken out to a plane not
    less than one metre below the subgrade level or the finished ground level in the area or to
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    immediately below the manhole and/or access shafts cover slab, whichever is the lower.
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    2 Manhole and access shaft walls shall be neatly trimmed off and reinforcement shall be cut or
    burned off close to the concrete and made safe.
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    3 Manholes and access shafts shall be cleaned out and all debris, sediment and refuse and
    other unsuitable material disposed of, and backfilled with approved compacted material.
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    2.10.10 Drainage Inlets and Gullies

    1 Unless shown otherwise, all redundant drainage inlets, gullies and similar facilities shall be
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    broken out to full depth.


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    2.11 DISPOSAL OF MATERIALS


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    1 Materials removed but not recovered shall be disposed of in a lawful manner at approved
    dumping areas. The Contractor shall be responsible for obtaining the location of the
    dumping area as well as the necessary permits and approvals from the relevant authorities.

    END OF PART
    QCS 2014 Section 06: Roadworks Page 1
    Part 03: Earthworks

    3 EARTHWORKS ....................................................................................................... 3
    3.1 GENERAL ............................................................................................................... 3
    3.1.1 Scope of Work 3
    3.1.2 References 3
    3.1.3 Definitions 4
    3.1.4 Submittals 4
    3.1.5 Quality Assurance 6
    3.2 EARTHWORKS BY OTHERS ................................................................................. 6
    3.3 MATERIALS ............................................................................................................ 6
    3.3.1 General 6
    3.3.2 Unsuitable Materials 7
    3.3.3 Fill and Subgrade Materials 7

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    3.3.4 Rock Fill 8

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    3.3.5 Water 9

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    3.3.6 Performance Indicators 9
    3.4 MAIN PLANT FOR EARTHWORKS ........................................................................ 9
    3.4.1
    3.4.2
    General
    Compaction Trials ta 10
    9
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    3.4.3 Rotary Cultivators 10
    3.4.4 Water Sprinklers 10
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    3.4.5 Bulldozers 10
    3.4.6 Motor Graders 11
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    3.4.7 Shovel Tractors 11


    3.4.8 Compacting Equipment 11
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    3.5 EXCAVATION GENERAL ..................................................................................... 12


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    3.5.1 Removal of Unsuitable Soil and Soft Spots 12


    3.5.2 Excavating High Level Areas 12
    3.5.3 Rock Excavation 13
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    3.5.4 Manual Excavation 13


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    3.5.5 Excavation for Pits and Trenches 14


    3.5.6 Double Handling 14
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    3.6 FILLING GENERAL ............................................................................................... 14


    3.6.1 General 14
    3.6.2 Filling Around Utilities 15
    3.6.3 Fill Supplied by Qatar National Transport Organization (QNTO) 15
    3.6.4 Contractors Imported Fill 15
    3.6.5 Rock Fill 16
    3.6.6 Compaction 17
    3.6.7 Filling of Pits and Trenches 18
    3.6.8 Work Over Sabkha 18
    3.6.9 Trimming Side Slopes 19
    3.7 STRUCTURE EXCAVATION AND FILLING .......................................................... 19
    3.7.1 General 19
    3.7.2 Excavation Supports 20
    3.7.3 Dewatering 20
    QCS 2014 Section 06: Roadworks Page 2
    Part 03: Earthworks

    3.7.4 Excavation for Structures 20


    3.7.5 Use of Materials 21
    3.7.6 Cofferdams 21
    3.7.7 Backfill Adjacent to Structures 22
    3.8 FORMATION PREPARATION............................................................................... 22
    3.8.1 Scope 22
    3.8.2 Protection 23
    3.8.3 Rectification 23
    3.9 TOPSOIL ............................................................................................................... 23
    3.10 TESTING ............................................................................................................... 23
    3.10.1 General 23
    3.10.2 Testing Degree of Compaction 24

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    3.10.3 California Bearing Ratio 24

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    3.10.4 Testing Levels and Evenness of the Formation 25
    3.10.5 Testing Formation Works after Completion 25

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    QCS 2014 Section 06: Roadworks Page 3
    Part 03: Earthworks

    3 EARTHWORKS

    3.1 GENERAL

    3.1.1 Scope of Work

    1 This Part includes all the earthworks required to construct and maintain the roadway facilities
    as follows:

    (a) Removing unsuitable materials.


    (b) Excavating selected material from the roadway and borrow pits for use as specified.
    (c) Placing and compacting of selected material.
    (d) Structure excavation.

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    (e) Backfilling.

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    (f) Supplying and placing topsoil (sweet soil).
    (g) Laying and compaction of fill for shallow embankments where additional slope
    protection measures are not required.

    2 Related Parts are as follows: ta


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    This Section
    Part 1, .............. General
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    Part 2, .............. Site Clearance


    Part 4, .............. Unbound Pavement Materials
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    Part 5, ............. Asphalt Works


    Part 6, ............. Concrete Road Pavements
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    Part 19, ........... Miscellaneous


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    Section 8, Drainage Works


    Section 12, Earthworks Related to Buildings
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    3.1.2 References
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    1 The following standards are referred to in this Part:


    ASTM D1556 .............Standard Test Method for Density and Unit Weight of Soil in Place by
    Sand-Cone Method
    ASTM D1557 .............Standard Test Methods for Laboratory Compaction Characteristics of
    3 3
    Soil Using Modified Effort (56,000 ft lbf/ft (2,700 kN m/m ))
    ASTM D4718 .............Standard Practice for Correction of Unit Weight and Water Content for
    Soils Containing Oversize Particles
    ASTM D1883 .............Standard Test Method for CBR (California Bearing Ratio) of
    Laboratory Compacted Soils
    ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
    Index of Soils
    ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
    soils using Sieve Analysis
    QCS 2014 Section 06: Roadworks Page 4
    Part 03: Earthworks

    ASTM D4429 ..............Standard Test Method for (California Bearing Ratio) CBR of Soils in
    Place
    ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
    Content of Soil by the Calcium Carbide Gas Pressure Tester
    ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
    and Soil-Aggregate by Nuclear Methods (Shallow Depth)
    ASTM D1140 ..............Standard Test Method for Amount of Material in Soils Finer than No.
    200 (75-m) Sieve
    ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
    Using a Straightedge

    AASHTO T307 ..........Standard Method of Test for Determining the Resilient Modulus of
    Soils and Aggregate Materials

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    BS 1377 - Part 3 ........Methods of test for Soils for Civil Engineering Purposes: Chemical and

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    electro-chemical tests

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    3.1.3 Definitions

    LSA: Laboratories and Standardization Affairs Ministry of Environment.


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    2 Suitable material: material which is acceptable in accordance with Clause 3.3.3.

    3 Imported material: suitable material obtained from outside of the Site.


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    4 Optimum moisture content (OMC): the moisture content of soil at which a specified
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    compaction effort will produce the maximum dry density when determined in accordance with
    ASTM D1557.
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    5 Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
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    effort at the optimum moisture content when determined in accordance with the modified
    compaction test ASTM D1557. Unit weight and moisture content of materials containing more
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    than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
    corrected following ASTM D4718.
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    6 Subgrade: the compacted existing ground or fill for 500mm beneath formation.
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    7 Formation: the completed earthworks level shaped in accordance with the Drawings in
    readiness to receive the sub-base.

    3.1.4 Submittals

    1 The Contractor shall submit to the Engineer for approval his proposals for the compaction of
    each type of material to be used in embankments detailing the type of plant, number of
    passes and maximum loose depth of layer.

    2 The contractor shall submit to the Engineer for approval method statements for the following:

    (a) Materials production, handling, storage, identification, marking and traceability to


    source of production.
    (b) Quality assurance and quality control plans for all construction activities.
    (c) Quality control testing plan.
    QCS 2014 Section 06: Roadworks Page 5
    Part 03: Earthworks

    (d) Equipment and its suitability to fulfill all construction activities to the required quality.
    (e) Personnel capability.
    (f) Safety and environment preservation measures.

    3 Before commencing any structural excavation work greater than 1.5 m in depth, the
    Contractor shall submit to the Engineer for his review details of proposals for supporting
    excavated faces.

    4 The proposals shall be submitted in the form of calculations and drawings which clearly
    indicate the extent of excavation at all points along the structure relative to adjacent
    properties, roads and services.

    5 In the case of supported excavations the proposals shall, for the actual soil properties,
    comprise detailed drawings of the support system stating method of installation and showing

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    support member materials, sizes, spacing and engineering calculations to validate the design

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    of the above, including the maximum theoretical deflections of the support members. The

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    support system shall be designed in such a manner that no support members extend through
    surfaces exposed in the finished construction and no shoring or bracing is placed under
    permanent structures.

    6 ta
    The engineering calculations shall be in English and shall show lateral earth pressures for the
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    full excavation depths, faces at various stages of support during installation and removal and
    concrete placement, the anticipated equipment loads, anchorage loads of any description,
    as

    the maximum design loads to be carried by various members of the support system and strut
    preload forces.
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    7 If the structure support system proposed includes tie-back anchors, the Contractor's
    submittal drawings shall show the profile of the soil in which each anchor is to be installed,
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    the design load for the full depth of the excavation, the maximum design and proof loads,
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    surcharge loads of any description; equipment loads, forces at various stages, support during
    installation and removal, and the criteria proposed for deformations under proof loads.
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    8 In addition to the approval submittal, shop drawings of the support system are to be
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    submitted. Where a proposed system of tie-back anchors projects onto adjoining property
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    beyond the vertical projection of the designated limits of the Contract, the permission of the
    owner shall be obtained in writing and documentation of such permission shall be included in
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    the submittal.

    9 Complete working drawings showing the type of dewatering and groundwater control system
    proposed shall be submitted for review. The submittal drawings shall show the arrangement,
    location and depths of the proposed dewatering system if required. A complete description of
    the equipment and materials to be used and the procedure to be followed shall be shown
    together with the standby equipment, standby power supply, and the proposed location or
    locations of points of discharge of water. Details of methods of cofferdam construction shall
    be included in the submittal.

    10 The method and the type of equipment to be used for advancing dewatering wellpoints shall
    be submitted for review.
    QCS 2014 Section 06: Roadworks Page 6
    Part 03: Earthworks

    3.1.5 Quality Assurance

    1 The designs of the structure excavation support systems and the dewatering system shall be
    prepared by and signed by a professional engineer specializing in this type of design work.

    2 Blasting work shall be carried out by a specialist company with the appropriate license as
    detailed in clause 3.5.3.

    3.2 EARTHWORKS BY OTHERS

    1 Where earthworks have been carried out by others before commencement of the Works, the
    Contractor shall carry out all tests he considers necessary to satisfy him that the work already
    executed complies with this specification.

    2 Should the Contractor consider the result of the tests unsatisfactory he shall immediately

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    provide full details of all such tests carried out for the Engineer's review as to the remedial

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    work to be undertaken.

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    3 The Contractor will be deemed to have satisfied himself as to the adequacy of any previous
    earthworks when he proceeds with his own work, and he shall be responsible for repairs to or

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    replacement of any defective layer or surface where such failure was due to a fault in the
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    previously executed work which would have been revealed by normal testing procedures.

    3.3 MATERIALS
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    3.3.1 General
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    1 All excavated material shall be the property of the Owner and shall not be removed from the
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    Site without the written consent from the Owner.


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    2 Suitable and approved excavated material from any part of the Site shall be hauled and used
    for filling in any other section of the Site. The Contractor shall store such material when
    necessary until the need arises for its use in filling as required by the phases of construction,
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    or as directed by the Engineer.


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    3 Where the amount of suitable material exceeds the amount of fill required for the Works, the
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    Contractor shall dispose of the surplus material at designated locations. The Contractor shall
    off-load, spread, level, water and carry out other related operations at the disposal site as
    directed by the Engineer. The Contractor shall ensure that the disposal site has been
    approved by the Municipality concerned.

    4 Any excavation greater than the net volume required for the Works in length or width, shall be
    made up with suitable compacted fill material at no cost to the Owner and subject to
    inspection and approval of the Engineer.

    5 Any additional excavation to remove unsuitable material at or below the bottom of foundation
    level or construction layers shall be replaced with mass concrete.

    6 Before using material resulting from excavation for filling, the Contractor shall carry out field
    and laboratory testing to establish the suitability of said material for filling work. Whenever
    such excavated material indicates a change in characteristics the Contractor shall carry out
    additional testing.
    QCS 2014 Section 06: Roadworks Page 7
    Part 03: Earthworks

    7 Where the contract provides for the supply of fill material by others the Contractor shall
    remain responsible for checking each load received to ensure that it is in accordance with the
    specification requirements and for rejecting unsuitable material. The Contractor shall be
    responsible for maintaining all records of deliveries and documentation relating to the quality
    of such material.

    3.3.2 Unsuitable Materials

    1 Unsuitable materials shall mean materials other than suitable materials and include;

    (a) Material from marshes.


    (b) Tree and plant stumps.
    (c) Perishable material.
    (d) Deposits of sabkha with more than 5% water-soluble salts.

    l .
    .l.
    (e) Material subject to spontaneous combustion.

    rw
    3.3.3 Fill and Subgrade Materials

    1
    ta
    The subgrade material and the material used for filling and compacting below the formation
    level of the roadway, sidewalks, hard shoulder, drainage ditches and other areas on site shall
    qa
    consist of material approved for filling resulting from the excavation works.

    2 In the event that such material is unsuitable or insufficient, the Contractor shall obtain and
    as

    use filling material from borrow pits.


    se

    3 This material shall be clean and free from any unsuitable material and complies with the
    requirements listed in Table 3.1.
    er

    4 The maximum particle size of fill material shall be 75 mm unless the material is classified as
    ov

    rock as per this part of the specification and the placing and compaction are carried out
    according to the requirements for rock fill.
    o

    5 Unit weight and moisture content of materials containing more than 5% by mass of oversize
    it

    fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
    et
    m

    6 When nuclear gauge is used for field density and moisture content testing, 3 readings shall
    be made at each test location within a radius of 2 meters. The average of the 3 readings is
    considered to be the density for that test location. Individual density readings shall not be less
    than the target relative density by more than 0.5%.

    7 Recycled aggregate produced from excavating natural ground and from demolition wastes
    can be used for filling purposes provided that the specifications stated in Section 6 - Part 9
    are complied.
    QCS 2014 Section 06: Roadworks Page 8
    Part 03: Earthworks

    Table 3.1
    1
    Fill and Subgrade Materials and Construction Specifications

    Parameter Standard Specification Limits Minimum Frequency

    Percent passing the


    ASTM D6913 100%
    75mm sieve
    Percent passing the
    ASTM D1140 30% max.
    0.075mm sieve - Each Source
    ASTM D4318
    Liquid limit 30% max. - Visible change in
    Method A
    material
    Plasticity Index ASTM D4318 10 % max.
    3
    - 1 per 1000 m
    California Bearing

    .
    ASTM D1883 15% min. at 95% MDD

    l
    Ratio (CBR)

    .l.
    (Soaked)
    Swelling 2% max.

    rw
    ASTM D6938 - 1 per 200 m
    2
    per
    Field Density Min. 95% of MDD
    ASTM D1556
    ta layer
    qa
    In Place Moisture ASTM D6938 - 1 every 75m per
    2 2% of OMC
    Content ASTM D4944 lane per layer
    as

    In Place California 2
    ASTM D4429 15% min. 1 per 2000 m
    Bearing Ratio (CBR)
    se

    Acid soluble Chloride


    BS 1377 Part 3 2% max.
    Content
    er

    3
    Acid soluble sulphate 1 per 3000 m
    BS 1377 Part 3 3% max.
    ov

    content
    Organic Matter BS 1377 Part 3 2% max.
    o

    1
    Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
    2
    During compaction.
    it
    et

    3.3.4 Rock Fill


    m

    1 Rock shall be defined as any naturally formed solid matter encountered in excavation having
    2 2
    a crushing strength of not less than 7 N/mm when dry and not less than 4 N/mm after
    submergence in water for 24 hours.

    2 This shall be determined on samples of 100 mm x 100 mm x 100 mm cubes obtained from
    the material (equivalent cores in lie u of cubes may be considered for testing at the discretion
    of the Engineer and the method of testing and acceptance criteria will be advised by the
    Engineer in such cases).

    3 Individual masses of solid material found in excavation and weighing less than 500 kg shall
    not be considered as rock.

    4 Any artificially formed solid matter such as block work or concrete shall not be considered as
    rock.
    QCS 2014 Section 06: Roadworks Page 9
    Part 03: Earthworks

    5 The Contractor shall supply any equipment and labor necessary to obtain suitable samples
    and carry out testing of rock or suspected rock. The Engineer shall determine the location
    and quantity of samples necessary to determine the extent of the rock. These samples shall
    be taken in the presence of the Engineer.

    6 In the event that the tests prove that the material is rock, the Engineer shall determine the
    extent of such material and shall instruct the Contractor accordingly.

    3.3.5 Water

    1 Potable or brackish water shall be used for all earthwork operations except that only potable
    water shall be used for compaction of backfill material within one meter from all surfaces of
    the structure and for the backfill of all service trenches.

    2 Brackish water shall have a maximum total dissolved solids (TDS) of 5000 ppm, a maximum

    l .
    chloride content of 1500 ppm and a maximum sulphate content (as SO3) of 2000 ppm.

    .l.
    rw
    3.3.6 Performance Indicators

    1 Upon the request of the Engineer, the following performance indicators shall be determined

    ta
    from loose in place materials for verification of the pavement structural design following the
    AASHTO Mechanistic-Empirical Pavement Design Guide:
    qa
    (a) Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture
    content and maximum density as per ASTM D1557.
    as

    (b) Parameters and moduli required for determining the Permanent Deformation Potential
    se

    in accordance with AASTHO Mechanistic Empirical Design Guide.


    (c) Parameters and moduli required for measuring the Fatigue Cracking Potential for
    er

    stabilized and surface layers in accordance with AASHTO Mechanistic Empirical


    ov

    Design Guide.
    3
    2 For performance testing, one sample shall be tested every 10,000 m , and for constructions
    3
    o

    having less than 10,000 m volume, one sample shall be tested every 50% of the total
    it

    volume.
    et

    3.4 MAIN PLANT FOR EARTHWORKS


    m

    3.4.1 General

    1 The Contractor shall provide the Engineer with copies of catalogues, technical data and
    charts of the machinery to be used on site before the commencement of the work.

    2 The Engineer will inspect the machinery and tools before the commencement of work. The
    machinery and tools used in carrying out earthworks and other related works for the road
    construction and in maintenance of the work shall be in good working condition, and the
    Contractor shall maintain them in such condition for the whole duration of the Work.

    3 The Contractor shall use power screens equipped with clay reject screen with sufficient
    screen area and clay reject conveyor belt when processing subgrade materials. Static
    screens shall not be used to produce subgrade materials. Any deviations from this process
    must be approved by the Engineer.
    QCS 2014 Section 06: Roadworks Page 10
    Part 03: Earthworks

    4 The Contractor shall supply an adequate type and number of machines and tools for the
    proper and timely execution of the Works. The number of machines shall not be limited to the
    types of equipment or recommended minimum number stipulated in the Contract
    Documents, which shall be used for guidance purposes only.

    5 The Contract is awarded on the understanding that the actual numbers of machines and
    other plant will not be reduced below the numbers shown in the Contract.

    6 No plant shall be removed from the site without the specific written approval of the Engineer.

    3.4.2 Compaction Trials

    1 Before commencing construction of the permanent works, unless otherwise agreed with the
    Engineer, the Contractor shall carry out compaction trial, after submitting a method
    statement, for each type of fill material and construction situation of the earthworks to

    l .
    establish an approved rolling/compaction procedure which shall then be used as a minimum

    .l.
    requirement for the permanent works unless otherwise directed or agreed by the Engineer.

    rw
    2 The compaction trials shall involve all procedures specified for the permanent works
    including testing and any equipment, processes or procedures as proposed by the Contractor

    ta
    which are not included as a part of these specifications. Compaction trials for each main type
    of material shall be carried out on areas having dimensions of approximately 50 meters by 10
    qa
    meters.
    as

    3 Construction of the permanent works shall not commence until a compaction procedure has
    been approved in writing by the Engineer.
    se

    3.4.3 Rotary Cultivators


    er

    1 Rotary Cultivators shall have axles rotated by a powerful motor and be equipped with metal
    ov

    teeth or plates. They shall be designed in such a way as to ensure proper pulverization and
    mixing of soil. They must be equipped with apparatus to lift and lower the axles so as to be
    always to the required depth.
    it o

    3.4.4 Water Sprinklers


    et

    1 Water sprinklers shall be borne by trucks with pneumatic tires and shall be equipped with a
    m

    pressure pump and water sprinkling distribution equipment. The pump shall be powered in
    such a manner that the pump pressure will remain uniform regardless of variations in truck
    speed. The distributors shall be so designed as to allow sprinkling and adding of water to the
    soil uniformly and in controlled quantities and shall be equipped with an approved gauge to
    control the quantity of water added during operation. Special spray bar attachments shall be
    provided and used in order to sprinkle water on sloped sections. The activation of the water
    system shall be controlled from the cab by the driver.

    3.4.5 Bulldozers

    1 Bulldozers may be tracked or pneumatic-tire vehicles and shall be equipped with a blade for
    earth moving and levelling. Ripper attachments shall be provided when necessary. The blade
    level shall be hydraulically controlled to raise or lower it so that the work surface can be
    formed and adjusted as required.
    QCS 2014 Section 06: Roadworks Page 11
    Part 03: Earthworks

    3.4.6 Motor Graders

    1 Motor graders shall be pneumatic-tire and shall be equipped such that it is possible to lift,
    lower and adjust the angle of the blade as required to control the grading operation and to
    perform grading without making undulations.

    3.4.7 Shovel Tractors

    1 Shovel tractors shall be tractors equipped with a shovel for earth hauling or moving and may
    be either on tracks or on pneumatic tires. The shovel shall be hydraulically controlled to raise
    and lower it as required.

    3.4.8 Compacting Equipment

    1 Rolling compacting equipment shall consist of pneumatic-tire and steel wheeled rollers as

    l .
    described below:

    .l.
    (a) Pneumatic-tire rollers shall be equipped with tires of equal size and diameter which

    rw
    shall be uniformly inflated so that the air pressure of the tires shall not vary
    significantly, from one another. The wheels shall be spaced so that one pass will

    ta
    accomplish one complete coverage equal to the rolling width of the machine. There
    shall be a minimum of 6mm overlap between the tracks of the front and rear tracking
    qa
    wheels. Self-propelled, pneumatic-tire rollers shall have a minimum weight of
    9 tons without ballast and a minimum weight of 18 tons with ballast.
    as

    (b) Steel wheeled rollers shall be of the following types:


    se

    (i) Three-wheeled rollers shall be self-propelled and equipped with a reversing


    clutch, a differential drive and with adjustable scrapers to keep the wheel
    er

    surface clean.
    (ii) Tandem rollers shall be self-propelled and equipped with reversing clutches and
    ov

    adjustable spring scrapers fitted to the driving and steering roller to scrape in
    both directions.
    o

    (iii) Vibratory steel tandem rollers shall have the requirements of the foregoing steel
    it

    tandem rollers with a static weight of at least 5000 kg and a vibrating frequency
    et

    between 1500 and 2000 cycles per minute.


    m

    (iv) Single drum vibratory steel rollers shall be double axle, self-propelled units with
    the rear axle equipped with pneumatic flotation wheels, they shall have vibrating
    frequency capabilities between 1500 and 2000 cycles per minute.

    2 Portable vibratory compaction rollers shall be double axle tandem single-drum self-propelled
    equipped with a vibrating element delivering an impact of not less than 1590 kg at a
    frequency of about 5000 cycles per minute. The roller shall be easily maneuvered, of
    adequate width and suitable for rolling ditches with their side slopes having grades of up to
    1:3.

    3 Hand plate compactors shall be capable of delivering an impact of between 750 to 1500
    kilograms.
    QCS 2014 Section 06: Roadworks Page 12
    Part 03: Earthworks

    3.5 EXCAVATION GENERAL

    3.5.1 Removal of Unsuitable Soil and Soft Spots

    1 If during the progress of the work the soil encountered has characteristics, as determined by
    tests conducted under the direction of the Engineer, that render it unsuitable for incorporation
    in the road embankment, the Contractor shall excavate and remove such unsuitable material
    to the extent directed by the Engineer.

    2 Where contractor finds isolated soft spots during excavation, this material shall be removed
    to the extent directed by the Engineer.

    3 No excavated suitable material shall be removed from the Site without the approval of the
    Engineer. Should the Contractor be permitted to remove suitable material to suit his

    .
    operational procedure then he shall make good any consequent deficit of fill material arising

    l
    .l.
    therefrom.

    rw
    4 Where the excavation reveals a combination of suitable and unsuitable material the
    excavation shall, unless otherwise agreed with the Engineer, be carried out in such a manner
    that the suitable materials are excavated separately for use in the Works without
    contamination by the unsuitable material.
    ta
    qa
    5 The hauling of excavated material to areas of fill shall proceed only when sufficient spreading
    and compacting plant are operating at the place of deposition to ensure placing and
    as

    compaction.
    se

    6 Unsuitable excavated material shall be removed and carted away to an approved dumping
    area after approval from the Engineer.
    er

    7 The Contractor shall replace this unsuitable material by other suitable surplus or imported
    ov

    material in layers not exceeding 150 mm compacted thickness to the density specified.

    8 If the contractor considers in some situations it is impractical to replace unsuitable material


    o

    with imported material he may elect to use granular material, which shall comply with the
    it

    requirements of part 4 of this specification.


    et

    9 Granular material placed beneath water shall not require compaction, granular material
    m

    placed above water shall be compacted and tested as per the requirements of part 4 of this
    specification.

    10 If any solution cavities are found in lime stone material they shall be brought to the attention
    of the Engineer. The Engineer shall advise what treatment is to be carried out in such
    situations.

    3.5.2 Excavating High Level Areas

    1 The Contractor shall excavate high level areas in all materials including rock for the full width
    of the road construction down to the top of the required subgrade.

    2 The Contractor shall then scarify a layer not less than 150 mm deep except that this
    requirement shall not apply where rock is present.
    QCS 2014 Section 06: Roadworks Page 13
    Part 03: Earthworks

    3 The soil shall be pulverized, watered as required, mixed, shaped and compacted to 95 %
    maximum dry density, as per ASTM D1557, to a depth of 150 mm.

    4 In all excavations the groundwater level shall be maintained at least 300 mm below the
    formation level during the works.

    3.5.3 Rock Excavation

    1 Excavation in rock shall be as defined in clause 3.3.4 of the specification.

    2 Excavation in rock may be carried out by a tracked bulldozer and ripper or by the use of
    blasting with explosives or any other method approved by the Engineer.

    3 Blasting using explosives shall only be permitted if authorized by the civil defense, police and
    any other statutory authority. The Contractors method statement shall be agreed before any

    l .
    .l.
    blasting operation.

    rw
    4 Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives
    in Qatar prepared by the former Ministry of Industry and Public Works.

    5
    ta
    For any blasting work involving the use of explosives the Contractor shall use a specialist
    qa
    company, licensed to carry out such work by the former Ministry of Industry and Public
    Works.
    as

    6 The specialist company shall possess the appropriate license for the required scope of work.
    se

    7 The purchase and delivery of each consignment of explosives for blasting work should be
    covered by a separate application for a possession license.
    er

    8 The transportation of explosives shall only be carried out after notification to the police and
    ov

    civil defense.

    9 For each planned blasting operation the Contractor shall arrange for advance notification to
    o

    be made to the police and civil defense authorities.


    it
    et

    10 After it has been established that the excavated material is rock and after the area where
    such rock exists has been defined, the Contractor shall incorporate the rock in the
    m

    embankment.

    11 When excavated material contains more than 25 % of rock larger than 150 mm in greatest
    diameter the rock shall be crushed, pulverized and further broken down. The resultant
    material from the excavation shall be placed on the embankment in accordance with clause
    3.6.5.

    3.5.4 Manual Excavation

    1 The Contractor shall excavate manually in the vicinity of all services, structures, and any
    other areas, and if necessary uncover them, all as directed by the Engineer.

    2 The Contractor shall take all precautions to prevent damages to services, properties and
    persons, and any damage resulting from the negligence of the Contractor, his agents, or his
    employees. Any such damage shall be repaired by the Contractor at his own expense.
    QCS 2014 Section 06: Roadworks Page 14
    Part 03: Earthworks

    3.5.5 Excavation for Pits and Trenches

    1 All trenches and pits under roads shall, where possible, be excavated, backfilled and
    compacted before road construction commences.

    2 The sides of the excavation shall be adequately supported at all times.

    3 Trenches and pits shall be kept free of water.

    4 In tidal and high water table areas the excavation shall be kept free from standing water at all
    times during construction.

    5 Trenches for pipes or ducts shall be excavated to the levels and gradients indicated in the
    contract documents.

    3.5.6 Double Handling

    l .
    .l.
    1 It shall be the Contractors responsibility to assess at the start of the contract the quantity of
    suitable material available from an excavation for use as fill material and the requirement for

    rw
    imported fill material.

    2
    ta
    The Contractor shall plan earthworks operations to minimize the handling of fill material and
    disruption due to dust and noise from transportation operations.
    qa
    3 The Contractor shall not be entitled to any additional payment for double handling of any
    excavated material from the site for imported fill.
    as

    4 If it is necessary to double handle the material the Contractor shall take all measures to avoid
    se

    degradation or contamination of fill material.


    er

    5 The Engineer may instruct that the tests to assess the properties of the fill material are taken
    at any point during the transportation, placing and compaction process.
    ov

    3.6 FILLING GENERAL


    it o

    3.6.1 General
    et

    1 Filling low-level areas shall be to the level of subgrade as designated. After completion of
    m

    clearing and grubbing, the Contractor shall carry out the necessary levelling in order to
    control the thickness of the layers of fill.

    2 The existing natural ground shall then be scarified in place to a minimum depth of 150 mm
    for the full width of the embankment except where the material is classified as rock. The
    scarified material shall be watered as required, thoroughly mixed, shaped and compacted to
    a minimum of 95 % maximum dry density.

    3 Where an existing embankment is being widened, the existing embankment slope shall be
    trimmed and compacted into benches of minimum width 1m and depth 500mm before
    placing and compacting each layer of new embankment material unless otherwise directed
    by the Engineer to suit particular circumstances.

    4 The Contractor shall not proceed with filling and compacting any subsequent layer before
    testing and securing the approval of the Engineer for the previous layer.

    5 All fill material for a depth of 500 mm below the formation level must meet the requirements
    provided in clause 3.3.3.
    QCS 2014 Section 06: Roadworks Page 15
    Part 03: Earthworks

    3.6.2 Filling Around Utilities

    1 Filling around culverts, storm water and sewerage pipes, utility and structures, and between
    building plot and footpath areas shall be done in accordance with the specific requirements of
    the relevant utility authority and the following additional requirements.

    2 Filling for these areas shall be from surplus excavated material obtained on site and
    approved by the Engineer. In the case of insufficiency of such material then approved
    material shall be obtained from borrow pits and filled to the designated levels. The maximum
    size of particle allowed in the backfill within one meter of culverts, storm water and sewage
    pipes, utilities and structures shall be 25 mm.

    3 The Contractor shall take every precaution to protect bridge columns and lighting equipment
    when filling between median barriers and any damage to these items arising from the filling
    works shall be repaired by the Contractor.

    l .
    .l.
    4 The Contractor shall agree the type of plant or equipment to be used with the Engineer

    rw
    before undertaking this work.

    3.6.3 Fill Supplied by Qatar National Transport Organization (QNTO)

    1 ta
    If instructed under the projects specification, fill will be imported from other sources using the
    qa
    Qatar National Transport Organization (QNTO).
    as

    2 It shall be the responsibility of the Contractor to monitor and control both the quality and the
    quantity of this imported fill.
    se

    3 The Contractor shall ensure that all delivery notes for such material are verified and
    authenticated and then collated for submission to the Engineer.
    er
    ov

    3.6.4 Contractors Imported Fill

    1 The project specifications shall designate areas for the Contractor to obtain borrow material
    o

    for use in the construction of the Works. It is the Contractor's responsibility to satisfy himself
    it

    that there is sufficient borrow material of suitable types.


    et

    2 The Contractor may elect to use alternative sources of borrow material.


    m

    3 It shall be the Contractor's responsibility to obtain all permits or permission and make any
    payments that may be required in acquiring the rights to borrow material whether the
    Contractor uses the designated areas or elects to use alternative areas. The Contractor shall
    ensure that the source of all borrowed material has been approved by the Municipality
    concerned.

    4 The Contractor shall obtain and supply to the Engineer representative samples from the
    borrow pits he intends to use. The Engineer will be afforded the opportunity to be present
    during the sampling operations.

    5 The Contractor will carry out the necessary laboratory and, if required, field testing to
    establish the suitability of the material for filling work and will advise the Engineer of the
    results. The Engineer will advise the Contractor whether such material is acceptable and
    whether the borrow pit is an approved source of borrow material.
    QCS 2014 Section 06: Roadworks Page 16
    Part 03: Earthworks

    6 The Contractor will test samples of the approved borrow pits material actually being imported
    onto the site, and should such material fail to meet the requirements of these Specifications,
    approval to the use of the borrow pits will be withdrawn and the Contractor shall immediately
    cease importation from the borrow pits until such time as the Engineer may approve
    alternative sources of material from within the same borrow pits based on sampling and
    testing as specified above.

    7 The Engineer will decide whether the material already imported from the concerned borrow
    pits can remain as placed on the site, or whether the Contractor shall remove and replace the
    said material at his own expense.

    8 Overburden and any unsuitable top layers at the borrow pit shall be stripped and stockpiled to
    the satisfaction of the Engineer. Upon completion of excavation the Contractor shall replace
    the overburden and unsuitable material, smooth the surface and leave the area clean and
    tidy to the satisfaction of the Engineer.

    l .
    .l.
    9 The Contractor's haul and traffic arrangements will be subject to the Engineer's approval

    rw
    before the work may be commenced.

    3.6.5 Rock Fill

    1 ta
    Material consisting predominantly of rock fragments of such a size that it cannot be placed in
    qa
    layers of the thickness allowed without crushing, or further breaking down, may be placed in
    the embankment in layers not exceeding twice the average size of the larger fragments.
    as

    2 No layer of rock fill shall exceed 800 mm loose thickness.


    se

    3 Rock fill shall be placed and spread so that the largest boulders and fragments are evenly
    er

    distributed, with the voids in-between completely filled with smaller fragments, sand or gravel,
    watered in if necessary.
    ov

    4 Each layer shall be bladed and leveled by a track laying tractor.


    o

    5 Quality control tests will not normally be performed on this material but each layer must be
    it

    approved in writing by the Engineer before the next is placed.


    et

    6 Embankment layers which consist of material that contains rock but also has sufficient
    m

    compatible finer material other than rock shall be placed and compacted as for soil
    embankments. Quality control tests will be made wherever the Engineer determines they are
    feasible.

    7 Compaction shall be carried out by a vibratory roller with the following minimum mass:

    Mass per Meter Width of Depth of Fill Minimum number of Passes of the
    Vibration Roll (kg/m) Layer ( mm ) Roller on each Layer
    2300 - 2900 400 5
    2900 - 3600 500 5
    3600 - 4300 600 5
    4300 - 5000 700 5
    >5000 800 5
    QCS 2014 Section 06: Roadworks Page 17
    Part 03: Earthworks

    3.6.6 Compaction

    1 The Contractor shall carry out the required compaction specified after grading and leveling
    the surface to be compacted. In areas to be filled, compaction shall include adding necessary
    soil, water and compacting the first layer in addition to subsequent layers up to the proposed
    levels.

    2 In areas already excavated down to the required level, compaction shall include adding the
    necessary water, and compacting the surface, in accordance with the procedure outlined in
    paragraphs 3 to 12 below.

    3 After carrying out the grading, leveling, scarifying and pulverizing of the soil layer the
    Contractor shall add the necessary amount of water to permeate the pulverized soil.

    4 The soil shall then be thoroughly turned after each addition of water so as to achieve

    l .
    homogeneous moisture content in the whole thickness of the layer.

    .l.
    rw
    5 Before compacting, samples of the pulverized soil shall be tested using a 'Speedy Moisture
    Device' (ASTM D4944) or similar instrument to measure the moisture content. If the moisture
    content is not within 2 % of the optimum moisture content as determined by ASTM D1557,

    ta
    the area represented by this sample shall be scarified and aerated or water added until the
    qa
    moisture content is within 2 % of the optimum moisture content. The soil shall then be
    primarily leveled in order to commence earth compaction.
    as

    6 After primary levelling referred to above, compaction shall be commenced by means of the
    approved rolling pattern.
    se

    7 Filling shall be in layers not exceeding 150 mm compacted thickness.


    er

    8 All areas including embankment roadway, medians, shoulders, sidewalks and verges shall be
    ov

    compacted to 95 % of Maximum Dry Density as determined by ASTM D1557 unless


    otherwise specified or directed by the Engineer.
    it o

    9 The rolling shall be carried out in the direction of the road axis until the soil reaches the
    et

    required density. In crowned sections, rolling shall start from both edges of the road in the
    direction of the road axis. If the road is super elevated, rolling shall commence from the lower
    m

    side and continue to the higher side. In order to compensate for the amount of water loss in
    evaporation during the course of compaction, additional quantities of water shall be added as
    required.

    10 Each layer shall be levelled and rolled to achieve uniform compaction free from undulations,
    soft spots and depressions.

    11 No layer shall be covered by the next layer until it has been tested, inspected and approved
    by the Engineer.

    12 The Contractor shall be responsible for reinstatement to the satisfaction of the Engineer of
    any layer damaged or disturbed after compaction and approval, by any means or cause,
    before placing the next layer.
    QCS 2014 Section 06: Roadworks Page 18
    Part 03: Earthworks

    3.6.7 Filling of Pits and Trenches

    1 The bottom of all excavations shall be formed to the lines and levels shown on the drawings.

    2 Any pockets of soft soil or loose rock in the bottom of pits and trenches shall be removed and
    the resulting cavities and any large fissures filled with suitable material and compacted to a
    minimum relative compaction of 95 % based on ASTM D1557.

    3 Prior to proceeding with filling, the base of the excavation shall be compacted to a minimum
    relative compaction of 95 % based on ASTM D1557.

    4 The full width of the compaction plant shall fit inside the surface area of the backfilling with
    sufficient space to permit adequate compaction. Under no circumstance shall compaction be
    carried out with plant straddling backfilled and existing surfaces.

    l .
    5 Trenches and pits shall be backfilled in layers not exceeding 150 mm compacted thickness

    .l.
    unless otherwise directed by the engineer.

    rw
    3.6.8 Work Over Sabkha

    1
    ta
    Where the road embankment passes over Sabkha areas with a high water table the
    contractor shall take special precautions during the construction.
    qa
    2 These precautions shall include but shall not be limited to the construction of suitable
    as

    temporary haul roads for all construction plant operating in the area.

    3 Haul roads shall be constructed using rock fill and geotextiles as necessary to ensure a safe
    se

    stable surface.
    er

    4 The use of geotextiles and geosynthetics shall be in accordance with Part 15 when used for
    ov

    the permanent embankment.

    5 If directed by the Engineer the Contractor shall construct embankments over Sabkha areas
    o

    with a surcharge of excess material that shall remain in place till all appreciable settlement
    it

    has stopped. The Contractor shall provide a means of monitoring the settlement. The
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    Engineer shall decide when appreciable settlement has stopped.


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    6 Unless a specific treatment in using geotextiles or geosynthetics is described elsewhere in


    the contract, work over Sabkha shall comprise of initially stabilizing the existing Sabkha area
    by laying and rolling rock fill layer type 1 according to Table 3.2. This operation should be
    continued by adding and rolling type 1 rock fill layer with steel vibratory roller till the layer is
    completely stabilized.

    7 A layer of geotextile fabric should be laid over the compacted type 1 pervious backfill.

    8 A layer of 50mm pervious backfill type 2 according to Table 3.2 should be laid over the
    stabilized layer to protect the geotextile fabric.

    9 Layer of 200mm thick rock fill type 1 should be laid over type 2 pervious backfill to receive the
    required road layers after the above operation.
    QCS 2014 Section 06: Roadworks Page 19
    Part 03: Earthworks

    Table 3.2
    Definition of Type 1 & 2 backfill materials
    Percentage Passing
    Size (mm)
    Type 1 Type 2
    152.0 Max. -
    125.0 85 - 100 -
    100.0 75 - 90 -
    50.0 45 - 65 -
    37.5 35 - 55 -
    19.0 20 - 35 100
    12.5 10 - 25 95 100

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    9.5 5 - 20 70 100

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    4.75 - 0 55

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    2.36 - 0 10
    0.075 - 03

    3.6.9 Trimming Side Slopes ta


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    1 Embankment side slopes shall be trimmed to the profiles and dimensions shown on the
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    contract drawings.

    The earthworks shall be trimmed to within 20 mm of the designated profile.


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    2
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    3 The side slopes shall be thoroughly compacted after trimming to ensure a hard surface.
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    4 Side slopes shall be tested for compaction in accordance with this part of the specification
    and the minimum density requirement shall be 95% of the maximum dry density as per
    ASTM D1557.
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    3.7 STRUCTURE EXCAVATION AND FILLING


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    3.7.1 General

    1 In addition to the work specified, the Contractor shall include all operations necessary to
    excavate and backfill as required for the construction of any structures installations and
    utilities.

    2 This work shall include necessary, pumping, dewatering, draining, sheeting, bracing, and the
    necessary supply and construction of cribs and cofferdams and their subsequent removal.

    3 The Contractor shall take all necessary precautions, to the satisfaction of the Engineer, to
    prevent loss of natural cementation in the existing subsoil during, and as a consequence of,
    dewatering operations.

    4 This work shall also include the furnishing and placing of approved foundation fill material or
    concrete to replace unsuitable material encountered below the foundation elevation of
    structures.
    QCS 2014 Section 06: Roadworks Page 20
    Part 03: Earthworks

    3.7.2 Excavation Supports

    1 Battered excavation slopes greater than 1.5 m high shall not be used without the express
    written permission of the Engineer. Where such permission is not granted or where only a
    part of the overall depth of an excavation is permitted to be with battered slopes all faces of
    excavations greater than 1.5 m high shall be supported.

    2 The Contractor shall submit his proposals for supporting excavated faces.

    3 Before commencing any structural excavation work greater than 1.5 m in depth, the
    Contractor shall obtain the Engineers approval of his proposals for supporting excavated
    faces.

    3.7.3 Dewatering

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    1 At locations where the excavation extends below the groundwater table, a dewatering system

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    shall be provided. This will effectively reduce the hydrostatic pressure and lower the

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    groundwater levels below excavation levels, as required for the safe and proper excavation of
    the work. It will result in obtaining a stable, dry subgrade for the execution of subsequent
    operations.

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    The Contractor shall design dewatering methods and settling basins so that no critical
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    amounts of soil, sand or silt are removed during either the initial operations or the
    construction operations. Complete working drawings showing the type of dewatering and
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    groundwater control system proposed shall be submitted to the Engineer for his review.
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    3 The Contractor's submitted drawings shall show the arrangement, location and depths of the
    proposed dewatering system if required. A complete description of the equipment and
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    materials to be used and the procedure to be followed shall be shown, together with the
    standby equipment, standby power supply, and the proposed location or locations of points of
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    discharge of water.

    4 Any required dewatering system design shall also include the measures taken to prevent
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    damage due to settlement of pavement, utilities, sewers, buildings and other structures
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    outside the excavation but within the area affected by the dewatering procedures.
    et

    5 Dewatering shall not be terminated without the approval of the Engineer and in the case of
    m

    structures retained by ground anchors dewatering shall not be terminated until the ground
    anchors have been stressed to the full working load and approved by the Engineer.

    3.7.4 Excavation for Structures

    1 The Contractor shall notify the Engineer sufficiently in advance of the beginning of any
    excavation so that cross-sectional elevations and measurements may be taken of the
    undisturbed ground.

    2 Trenches or foundation pits for structures or structure footings shall be excavated to the
    designated lines and grades or elevations. They shall be of sufficient size to permit the
    placing of structures or structure footings of the full width and length shown. The designated
    elevations of the bottoms of footings shall be considered as approximate only and the
    Engineer may order, in writing, such changes in dimensions or elevations of footings as may
    be deemed necessary, to secure a satisfactory foundation.
    QCS 2014 Section 06: Roadworks Page 21
    Part 03: Earthworks

    3 Boulders, logs, and any other unsuitable material encountered in excavations shall be
    removed from the site.

    4 Unless otherwise designated structure excavation shall be carried out for a width of at least
    500 mm beyond the horizontal outside limits of the foundation, footing, box culvert or
    structural member to which the excavation relates. Concrete blinding or sub-foundations are
    not to be considered as structure for the purpose of defining such excavation.

    5 If during the progress of the work, loose or improperly compacted soil or such other material
    as the Engineer considers would be detrimental to load distribution of new foundations to the
    underlying soil is encountered below the structure foundation level such material shall be
    removed within the limits as directed by the Engineer.

    6 The resulting void shall be backfilled with either blinding concrete or with suitable material
    compacted to a density not less than 95 % of the maximum dry density as per ASTM D1557.

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    The Engineer shall specify the type of backfill to be employed at each location.

    rw
    7 After each excavation is completed, the Contractor shall notify the Engineer to that effect,
    and no footing, bedding material or pipe culvert shall be placed until the Engineer has
    approved the depth of excavation and the character of the material on which the foundations
    will bear.
    ta
    qa
    8 All rock or other hard foundation material shall be cleaned of all loose material and cut to a
    firm surface, either level, stepped, or serrated as directed by the Engineer. All seams or
    as

    crevices shall be cleaned and grouted. All loose and disintegrated rock and thin strata shall
    be removed. When the footing is to rest on material other than rock, excavation to final grade
    se

    shall not be made until just before the footing is to be placed.


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    3.7.5 Use of Materials


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    1 All excavated material, so far as it is suitable, shall be used as backfill or roadway fill.

    2 All excavated material shall be approved by the Engineer before being used as fill. All surplus
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    excavated material and excavated material rejected by the Engineer for use on the site shall
    it

    be removed from the site and disposed of in locations approved by the Engineer.
    et
    m

    3 Where the Engineer designates a disposal location this shall be within a 50 km radius of the
    site of the Works.

    3.7.6 Cofferdams

    1 Suitable and practically watertight cofferdams shall be used wherever water-bearing strata
    are encountered above the elevation of the bottom of the excavation.

    2 Cofferdams or cribs for foundation construction shall, in general, be carried well below the
    bottoms of the footings and shall be well braced and as nearly watertight as practicable. In
    general, the interior dimensions of cofferdams shall be such as to give sufficient clearance
    for the construction of forms and the inspection of their exteriors, and to permit pumping
    outside of the forms. Cofferdams or cribs which are tilted or moved laterally during the
    process of sinking shall be righted or enlarged so as to provide the necessary clearance.
    QCS 2014 Section 06: Roadworks Page 22
    Part 03: Earthworks

    3 When conditions are encountered which, as determined by the Engineer, render it


    impracticable to dewater the foundation before placing the footing, the Engineer may require
    the construction of a concrete foundation seal of such dimensions as he may consider
    necessary, and of such thickness as to resist any possible uplift. The concrete for such a seal
    shall be placed as directed by the Engineer. The foundation shall then be dewatered and the
    footing placed.

    4 If weighted cribs are employed and the weight is used to overcome partially the hydrostatic
    pressure acting against the bottom of the foundation seal, special anchorage's such as
    dowels or keys shall be provided to transfer the entire weight of the crib to the foundation
    seal. When a foundation seal is placed under water, the cofferdam shall be vented or ported
    at low water level as directed.

    5 As an alternative to a cofferdam, the Contractor may propose a wellpoint dewatering system,


    for approval by the Engineer, to keep structural excavation works dry. Such proposal shall

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    include, but not be limited to, sufficient calculations, sketches and drawings, to justify the

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    wellpoint positions and lengths in addition to pumping capacity required. The use of a

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    wellpoint dewatering system may not preclude the use of support or shoring within the
    excavation to provide adequate stability and safety to the satisfaction of the Engineer.

    3.7.7 Backfill Adjacent to Structures


    ta
    qa
    1 Excavated areas around structures shall be backfilled with suitable excavated materials or
    imported materials as approved by the Engineer. Backfill materials shall be placed in
    as

    horizontal layers not over 150 mm in depth and compacted to a minimum of 95% of the
    maximum dry density obtained by ASTM D1557.
    se

    2 Material used for backfill adjacent to structures shall have a sulphate content of less than
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    2.5 g/L when tested in accordance with BS 1377.


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    3 Each layer shall be moistened or dried as required and thoroughly compacted as specified.
    The maximum size of particle allowed in the backfill within one meter of structures shall be 50
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    mm.
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    4 Backfill and embankment behind walls of any culvert shall not be placed until the top slab of
    et

    the culvert has been placed and cured.


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    5 Backfill to culvert walls shall be carried out simultaneously behind opposite walls.

    3.8 FORMATION PREPARATION

    3.8.1 Scope

    1 This work shall consist of the preparation of the graded formation upon which sub-base, base
    course or pavement materials are to be placed, all in accordance with these Specifications.

    2 All subgrade shall be compacted to the previous requirements of these Specifications.

    3 Preparation and surface treatment of the formation shall be carried out after all duct and pipe
    installations in the subgrade have been completed.
    QCS 2014 Section 06: Roadworks Page 23
    Part 03: Earthworks

    4 Any non-compliant subgrade material shall be excavated, replaced, and compacted to the
    required density.

    3.8.2 Protection

    1 Once prepared, the formation shall be maintained in the finished condition until the first
    succeeding course of sub-base, base, or asphalt pavement material has been placed.

    2 The Contractor shall take all precautions necessary to protect the formation from damage:
    hauling over finished subgrade shall be limited to that which is essential for construction
    purposes.

    3 Any equipment used for hauling over the prepared subgrade which in the opinion of the
    Engineer is causing undue damage to the prepared subgrade or to the underlying materials
    shall be removed from the Works at the request of the Engineer.

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    4 All cuts, ruts and breaks in the surface of the subgrade shall be repaired by the Contractor

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    before placing any subsequent layer. The Contractor shall protect the prepared subgrade
    from both his own and public traffic.

    5
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    The Contractor shall maintain the subgrade by blading and rolling as frequently as may be
    necessary to preserve the subgrade in a completely satisfactory condition.
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    3.8.3 Rectification
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    1 Any surface area of the formation which is too high shall be graded off, scarified and re-
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    compacted to the full depth of the affected layer.

    2 Any surface area of the formation which is too low shall be scarified and corrected by the
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    addition of subgrade material of the same classification and moisture content.


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    3 The Contractor shall carry out additional testing as required by the Engineer to ensure that
    the standard of compaction is satisfactory through the full depth of a layer or previously
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    placed layers.
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    3.9 TOPSOIL
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    1 Topsoil (sweet soil) shall be fertile, free draining, non-toxic soil capable of sustaining healthy
    plant growth.

    2 The material proposed for use as topsoil shall be approved by the Agricultural Department of
    the Ministry of Municipal Affairs and Agriculture.

    3 Topsoil shall be loosely placed at the designated thickness.

    3.10 TESTING

    3.10.1 General

    1 For verification of material, moisture content, compaction, thickness and other properties of
    the materials or workmanship the Engineer shall at all times have access to all portions of the
    works and sites. All sampling and testing of material and work shall be carried out under the
    direction of the Engineer.
    QCS 2014 Section 06: Roadworks Page 24
    Part 03: Earthworks

    2 The minimum frequency of testing shall follow the frequencies mentioned in Table 3.1 unless
    more frequent tests are shown elsewhere in the contract documents or directed by the
    Engineer. Other testing shall be carried out as directed by the Engineer.

    3.10.2 Testing Degree of Compaction

    1 Testing shall be done in accordance with ASTM methods of testing, or other approved
    equivalent test or designated procedure.

    2 The density-in-place of earthworks layers shall be tested by the sand replacement method
    (ASTM D 1556) or nuclear method (ASTM D6938).

    3 Nuclear density gauge testing should only be carried out by personnel who have approved
    user certification issued by the Ministry of Environment.

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    4 Each in-situ density nuclear gauge shall be calibrated and a calibration form issued. The

    .l.
    Contractor shall maintain on site and with the instrument a copy of the Ministry of

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    Environment safety and training manual for the use of nuclear density gauges.

    5 When nuclear gauge is used for field density and moisture content testing, the density and

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    moisture content for each material shall be verified by measurements in accordance with
    ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
    qa
    be used as the calibration point value for each material.
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    6 When determining the laboratory maximum dry density the method described in ASTM
    D1557 shall be applied.
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    7 No person or company will be permitted to determine in situ density by means of a nuclear


    type density measuring device without complying with the requirements of the Ministry of
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    Environment. Refer to clause 1.5 of part 1 of this Section.


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    8 The density of any layer requiring compaction shall be determined in accordance with the
    specifications mentioned in Table 3.1.
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    9 If a layer does not conform to the required density, additional tests may be taken to
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    determine the limits of the failing area, after which the Contractor shall rework the area until
    the specified density is obtained. The Contractor shall allow enough time in his daily work
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    program to permit the performance and checking of the above tests, before he proceeds into
    any subsequent operations.

    3.10.3 California Bearing Ratio

    1 The soaked value of the California Bearing Ratio shall be determined on specimens
    compacted at the optimum moisture content and 95 % of the maximum dry density as per
    ASTM D1557 after soaking for 4 days in accordance with ASTM D1883. CBR value shall
    comply with the minimum requirement as per Qatar Highway Design Manual (QHDM).

    2 The test surcharge to be used for the equivalent pavement thickness shall be designated by
    the Engineer.
    QCS 2014 Section 06: Roadworks Page 25
    Part 03: Earthworks

    3.10.4 Testing Levels and Evenness of the Formation

    1 The Engineer shall test the levels and evenness of the finished formation surface to ascertain
    compliance.

    2 The Contractor shall make available to the Engineer a three-meter straight-edge and a crown
    template of sturdy and approved design and the necessary labor to assist in the checking
    operations.

    3 When tested in accordance with ASTM E1703 by a three-meter straight-edge placed at right
    angles to, or parallel to, the road centerline or when tested by a crown template placed
    centrally at right angles to the road centerline, the maximum gap between the road formation
    surface and the testing edge shall not be greater than 20 mm. Measurements shall be carried
    out at maximum spacing of 50m of road length for each lane.

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    4 The subgrade shall be prepared to the levels shown on the contract drawings to a tolerance

    .l.
    of between 15 mm and 20 mm when checked by a level instrument.

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    5 Variation in the falls to cross-sections of the road shall not exceed 0.4 %.

    6
    ta
    These tests shall be made at any point requested by the Engineer. In the event of any failure,
    qa
    the Contractor shall correct the unevenness of the surface and resubmit the area for approval
    by the Engineer.
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    3.10.5 Testing Formation Works after Completion


    se

    1 All completed works shall be inspected at any time as directed by the Engineer in order to
    verify the compliance of the executed work to the requirements of the contract as per
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    requirement of Part 5 in Section 3.


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    END OF PART
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    QCS 2014 Section 06: Roadworks Page 1
    Part 04: Unbound Pavement Materials

    4 UNBOUND PAVEMENT MATERIALS ..................................................................... 2


    4.1 GENERAL ............................................................................................................... 2
    4.1.1 Scope 2
    4.1.2 References 2
    4.1.3 Definitions 3
    4.1.4 Submittals 3
    4.1.5 Quality Assurance 4
    4.2 MATERIALS ............................................................................................................ 4
    4.2.1 Sources of Materials 4
    4.2.2 Storage and Handling of Materials 4
    4.2.3 Inspection Testing and Control 5

    .
    4.2.4 Fine Aggregate 5

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    4.2.5 Coarse / Combined Aggregate 6

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    4.2.6 Recycled Aggregate 7
    4.2.7 Water 8
    4.2.8 Performance Indicators 8
    4.3 ta
    MAIN EQUIPMENT ................................................................................................. 8
    qa
    4.3.1 General 8
    4.3.2 Paving Machines 9
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    4.3.3 Central Mixers 9


    4.4 MIX DESIGNS ......................................................................................................... 9
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    4.5 SCREENING AND MIXING ..................................................................................... 9


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    4.6 SPREADING AND COMPACTION ........................................................................ 10


    4.7 CORRECTIVE ACTION......................................................................................... 11
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    4.8 PROTECTION OF SURFACE ............................................................................... 11


    4.9 TESTING ............................................................................................................... 12
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    4.9.1 General 12
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    4.9.2 Thickness 12
    4.9.3 Evenness and Level 12
    m
    QCS 2014 Section 06: Roadworks Page 2
    Part 04: Unbound Pavement Materials

    4 UNBOUND PAVEMENT MATERIALS

    4.1 GENERAL

    4.1.1 Scope

    1 This Part includes materials, equipment and construction requirements for unbound layers
    (aggregate Subbase and Road Base courses).

    2 Related Parts are:


    Part 1 General
    Part 3 Earthworks
    Part 5 Asphalt Works

    l .
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    4.1.2 References

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    1 The following standards are referred to in this Part:

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    ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium
    qa
    Sulphate or Magnesium Sulphate
    ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size
    Coarse Aggregate by Abrasion and Impact in the Los Angeles
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    Machine
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    ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse
    Aggregates
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    ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size


    Coarse Aggregate by Abrasion and Impact in the Los Angeles
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    Machine
    ASTM D1556 ..............Standard Test Method for Density and Unit Weight of Soil in Place by
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    Sand-Cone Method
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    ASTM D1557 ..............Standard Test Methods for Laboratory Compaction Characteristics of


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    Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))


    ASTM D1883 ..............Standard Test Method for CBR (California Bearing Ratio) of
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    Laboratory-Compacted Soils
    ASTM D2216 ..............Test Methods for Laboratory Determination of Water (Moisture)
    Content of Soil and Rock by Mass
    ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
    Aggregate
    ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
    Index of Soils
    ASTM D4429 ..............Standard Test Method for CBR (California Bearing Ratio) of Soils in
    Place
    ASTM D4791 ..............Standard Test Method for Flat Particles, Elongated Particles, or Flat
    and Elongated Particles in Coarse Aggregate
    ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
    Content of Soil by the Calcium Carbide Gas Pressure Tester
    QCS 2014 Section 06: Roadworks Page 3
    Part 04: Unbound Pavement Materials

    ASTM D5821 ..............Standard Test Method for Determining the Percentage of Fractured
    Particles in Coarse Aggregate
    ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
    Soils Using Sieve Analysis
    ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
    and Soil-Aggregate by Nuclear Methods (Shallow Depth)
    ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
    Using a Straightedge
    AASHTO T307 ...........Standard Method of Test for Determining the Resilient Modulus of
    Soils and Aggregate Materials
    BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and
    electro-chemical tests

    4.1.3 Definitions

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    1 LSA: Laboratories and Standardization Affairs Ministry of Environment.

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    2 Optimum moisture content (OMC): the moisture content of soil at which a specific
    compaction effort will produce the maximum dry density when determined in accordance with
    the ASTM D1557.
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    3 Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
    effort at the optimum moisture content when determined in accordance with the modified
    as

    compaction test ASTM D1557. Unit weight and moisture content of materials containing more
    than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
    se

    corrected following ASTM D4718.


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    4 Subgrade: the compacted existing ground or fill for 500mm beneath formation.
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    5 Formation: the compacted subgrade level shaped in readiness to receive the Subbase or
    Road Base courses.
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    6 Subbase: It is the layer between the subgrade and the Road Base. It consists of compacted
    it

    selected granular materials.


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    7 Road Base: It is the layer directly beneath the asphalt course layers and above the subbase
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    or subgrade layer. It consists of compacted selected materials. It can be untreated or treated


    with suitable stabilizing admixtures.

    4.1.4 Submittals

    1 The Contractor shall submit recent test results for the proposed sources of materials for all
    quality requirements of the Contract. The Contractor shall submit a test certificate that proves
    that the raw materials that are purchased/used comply with specifications. The testing may
    be performed by an approved private laboratory or by the laboratory associated with the plant
    itself.

    2 The contractor shall submit to the Engineer for approval method statements for the following:

    (a) Materials production, handling, storage, identification, marking and traceability to


    source of production.
    (b) Quality assurance and quality control plans for all construction activities.
    QCS 2014 Section 06: Roadworks Page 4
    Part 04: Unbound Pavement Materials

    (c) Materials production, handling, storage, identification and marking, traceability to


    source of production.
    (d) Quality control testing plan.
    (e) Equipment and its suitability to fulfill all construction activities to the required quality.
    (f) Personnel capability.
    (g) Safety and environment preservation measures.

    4.1.5 Quality Assurance

    1 If requested the Contractor shall arrange for the Engineer to visit the source of the materials
    and jointly take samples for testing. The Contractor shall carry out testing as directed by the
    Engineer.

    .
    4.2 MATERIALS

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    4.2.1 Sources of Materials

    1 The Contractor shall notify the Engineer of the proposed sources of materials. The

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    Contractor shall ensure that the sources of all aggregates have been approved by the
    Municipality concerned.
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    2 The Engineer shall approve the sources before delivery of materials to the site.
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    3 Where a proposed source of material is not approved, the Contractor shall propose an
    alternative source of material.
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    4.2.2 Storage and Handling of Materials


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    1 Materials shall be so stored and handled as to assure the preservation of their quality and
    fitness for use in the works. Even after source approval has been given materials may again
    be inspected and tested before use in the work.
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    2 Stored material shall be located so as to facilitate prompt inspection.


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    3 All storage sites shall be restored to their original condition before acceptance of the Works.
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    4 Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
    or contamination of the various sizes. Stockpiles shall be kept flat, and the formation of high
    cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling
    aggregates the Engineer may require the use of baffled chutes or perforated chimneys.

    5 When trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at
    a time with trucks depositing their loads as close to the previous load as possible. The use of
    tractors or loaders to push material deposited at one location to another location in the
    stockpile shall not be allowed during the construction of the stockpile and their use shall be
    limited to levelling the deposited material only.

    6 The Contractor shall take all necessary protection measures in the storage, handling and
    stockpiling of materials to prevent contamination of materials by dust. The measures that the
    Contractor proposes to take shall be subject to the approval of the Engineer.
    QCS 2014 Section 06: Roadworks Page 5
    Part 04: Unbound Pavement Materials

    4.2.3 Inspection Testing and Control

    1 Loose materials for testing and acceptance shall be sampled from the un-compacted in-place
    layer.

    2 For verification of plant weights and measures, character of materials used in the preparation
    of the mixes, testing and other quality control requirements, the Engineer shall at all times be
    provided access to all portions of the mixing plant, aggregate plant, storage yards, crushers
    and other facilities used for producing and processing the materials of construction.

    3 The Engineer shall have authority to take samples and perform tests on any material
    supplied to the site from any source whatsoever in order to establish compliance and to
    accept or reject as he deems necessary. Samples shall also be taken from completed work
    to determine compliance. The frequency of all sampling and testing shall be as designated by
    the Engineer.

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    4 The Contractor shall provide suitable facilities at the quarry or plants to carry out all

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    necessary tests on the raw materials and mixes.

    5 The Contractor shall arrange for obtaining specimens of materials and samples taken from

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    stockpiles, including the provision of any necessary equipment and plant. This work shall be
    performed in the presence of the Engineer if so directed by the Engineer.
    qa
    6 Materials that are not in compliance shall be rejected and removed immediately from the site
    as

    of the works unless otherwise instructed by the Engineer.


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    7 Where defects in the materials or the completed work have been corrected, the Contractor
    shall not proceed with subsequent work until approval has been given by the Engineer.
    er

    4.2.4 Fine Aggregate


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    1 Fine aggregate (passing the 4.75 mm sieve) shall consist of crushed mineral aggregate
    and/or natural sand.
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    2 The fine aggregate shall be clean and free from clay-balls and other extraneous or
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    detrimental materials.
    m

    3 Where the source of fine aggregate does not meet the requirements listed in Table 4.1, the
    Contractor may, with the Engineer's approval, add fine aggregate and filler to correct the
    gradation or to change the characteristics of the material passing the 0.425mm sieve so as to
    meet the requirements. Such additional material shall be added in a manner which ensures a
    completely homogeneous material.
    QCS 2014 Section 06: Roadworks Page 6
    Part 04: Unbound Pavement Materials

    Table 4.1
    Specifications of fine aggregates for Road Base and Subbase layers

    Specification Limits
    Parameter Standard Minimum Frequency
    Road Base Subbase

    Liquid Limit ASTM D4318 25%max. 25% max.

    - Each source
    Plasticity Index ASTM D4318 6 % max. 6 % max.
    - Visible change in material
    3
    Sand equivalent ASTM D2419 35 min. 25 min. - 1 test every 1000m

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    Organic content BS 1377
    0.5% max. 0.5% max.
    Part 3

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    4.2.5 Coarse / Combined Aggregate

    1 ta
    Coarse aggregate (retained on the 4.75 mm sieve) shall consist of crushed stone or crushed
    qa
    gravel and shall be free from organic matter, clay and other extraneous or detrimental
    materials.
    as

    2 The required properties of coarse aggregates for Road Base and Subbase layers are listed in
    se

    Table 4.2.
    Table 4.2
    er

    Specifications of coarse aggregates for Road Base and Subbase layers


    ov

    Specification Limits
    Parameter Standard Minimum Frequency
    Road Base Subbase
    it o

    Fractured Faces ASTM D5821 50% min. 50% min.


    et

    - Each source
    Flat and Elongated
    m

    ASTM D4791 10% max. 15% max.


    Particles (5:1) - Visible change in

    ASTM C131 material


    Loss by Abrasion 30% max. 40% max.
    ASTM C535 3
    - 1 test every 3000m
    Soundness
    ASTM C88 15% max. 20% max.
    (5 cycles by MgSO4)

    3 Loose materials for testing and acceptance shall be sampled from the un-compacted in-
    place layer.

    4 The required properties of combined aggregate for Road Base and Subbase layers are listed
    in Table 4.3.

    5 Unit weight and moisture content of materials containing more than 5% by mass of oversize
    fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
    QCS 2014 Section 06: Roadworks Page 7
    Part 04: Unbound Pavement Materials

    6 When nuclear gauge is used for field density and moisture content testing, 3 readings shall
    be made at each test location within a radius of 2 meters. The average of the 3 readings is
    considered to be the density for that test location. Individual density readings shall not be less
    than the target relative density by more than 0.5%.

    7 When nuclear gauge is used for field density and moisture content testing, the density and
    moisture content for each material shall be verified by measurements in accordance with
    ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
    be used as the calibration point value for each material.

    8 In case abnormally high relative density values are encountered, it will be required to re-
    evaluate the related field and laboratory density values.

    9 Gradation requirements of combined aggregate for Road Base and Subbase layers are listed
    in Table 4.4.

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    4.2.6 Recycled Aggregate

    rw
    1 Recycled aggregate produced from excavating natural ground and from demolition wastes
    can be used in subgrade and subbase layers provided that the specifications stated in
    Section 6 - Part 9 are complied.
    ta
    qa
    Table 4.3
    1
    Specifications of combined aggregates for Road Base and Subbase layers
    as

    Specification Limits
    Parameter Standard Minimum Frequency
    se

    Road Base Subbase


    3 3
    2.15 Mg/m 2.05 Mg/m
    er

    Maximum Dry Density ASTM D1557 - Each source.


    min. min.
    ov

    Gradation ASTM D6913 Table 4.4 Table 4.4 - Visible change in


    California Bearing material
    ASTM D1883 80% min. 70% min.
    Ratio (CBR)
    o

    3
    (Soaked) - 1 test per 1000m
    it

    Swelling 0.5% max. 1.0% max.


    et

    ASTM D6938 - 1 per 200 m per


    2
    Field Density 100% of MDD 100% of MDD
    m

    ASTM D1556 layer


    In Place Moisture ASTM D6938 - 1 every 75m per
    2 1.5% of OMC 2% of OMC lane per layer
    Content ASTM D4944
    In Place California 2
    ASTM D4429 80% min. 70% min. 1 per 2000 m
    Bearing Ratio (CBR)
    Acid soluble Chloride
    BS 1377 Part 3 2% max. 2% max.
    Content 3
    1 per 3000 m
    Acid soluble sulphate
    BS 1377 Part 3 3% max. 3% max.
    content
    1
    Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
    2
    During compaction.
    QCS 2014 Section 06: Roadworks Page 8
    Part 04: Unbound Pavement Materials

    Table 4.4
    Gradation limits for Road Base and Subbase layers

    Sieve Size Road Base Subbase

    50.0 mm 100 100


    37.5 mm 95 100 90 100
    19.0 mm 70 92 70 90
    9.5 mm 50 70 45 - 75
    4.75 mm 35 55 30 60
    0.600 mm 12 25 10 30
    0.075 mm 08 0 12

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    4.2.7 Water

    1 Sea, brackish or saline water shall not be used in the mixing, spreading and compacting
    operations for Road Base / Subbase layers.
    ta
    qa
    4.2.8 Performance Indicators
    as

    1 Upon the request of the Engineer, the following performance related indicators shall be
    determined from loose in place materials for verification of the pavement structural design
    following the AASHTO Mechanistic-Empirical Pavement Design Guide:
    se

    (a) Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture
    er

    content and maximum density as per ASTM D1557.


    ov

    (b) Parameters and moduli required for determining the Permanent Deformation Potential
    in accordance with AASTHO Mechanistic Empirical Design Guide.
    o

    (c) Parameters and moduli required for measuring the Fatigue Cracking Potential for
    it

    stabilized and surface layers in accordance with AASHTO Mechanistic Empirical


    et

    Design Guide.
    3
    m

    2 For performance testing, one sample shall be tested every 10,000 m , and for constructions
    3
    having less than 10,000 m volume, one sample shall be tested every 50% of the total
    volume.

    4.3 MAIN EQUIPMENT

    4.3.1 General

    1 Unless otherwise stipulated herein the provisions of Section 6, Part 3 (Earthworks), in respect
    of the main machinery and tools used in earthworks construction, shall be adhered to,
    subject to the modifications and additions in this clause.

    2 The Contractor shall not be allowed to use any equipment or plant before obtaining the
    approval of the Engineer, and the Contractor shall undertake sound technical methods in
    operation and to engage skilled and trained operators, mechanics and labor to carry out the
    works.
    QCS 2014 Section 06: Roadworks Page 9
    Part 04: Unbound Pavement Materials

    3 The Engineer shall have the right to stop the use of any equipment or plant which he deems
    to be inferior to the quality required and to instruct the removal of such equipment and to
    have it replaced by suitable equipment or to alter the method of operation at any time he so
    desires.

    4 The Contractor shall immediately comply with such instructions without being entitled to any
    indemnities or extensions as a result of such instructions.

    5 The Engineer shall have the right to expel any operators, mechanics or labor and to instruct
    suitable replacement thereof at any time he deems such action is necessary.

    4.3.2 Paving Machines

    1 Paving machines shall be self-propelled and shall be capable of spreading the Subbase and
    Road Base materials in one operation so as to make it ready for compaction with minimum

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    shaping.

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    rw
    2 The paving machines shall be provided with a screed that strikes off and distributes the
    material to the required width and level.

    3
    ta
    The width of each spread shall not be less than a traffic lane wide.
    qa
    4 The screed shall be adjustable to the required width being laid.
    as

    5 Screed action includes any practical motion that produces a finished surface texture of
    uniform appearance.
    se

    4.3.3 Central Mixers


    er

    1 A central mixing plant shall be either of an approved drum or pugmill type with a moisture
    ov

    control system so that the material may be spread without further mixing or processing.

    2 Means shall be provided for regulating the flow of material to the mixer. The various feeds
    o

    shall be calibrated to allow adjustments to the mix design to be carried out.


    it
    et

    4.4 MIX DESIGNS


    m

    1 Aggregate Subbase and Road Base courses shall consist of crushed mineral aggregates or
    natural mineral aggregates of the designated gradation and thickness.

    2 The maximum dry density and the optimum moisture content of the material shall be
    ascertained as per the test procedure given in ASTM D1557 and this shall be used to assess
    the degree of compaction of the mix after rolling.

    3 The pavement layer designated as sub-base may be substituted by any of the materials
    designated to be laid on it subject to the approval of the Engineer.

    4.5 SCREENING AND MIXING

    1 Screening shall be required for the materials used in Subbase and Road Base courses to
    ensure that the designated gradation is attained.
    QCS 2014 Section 06: Roadworks Page 10
    Part 04: Unbound Pavement Materials

    2 Screens shall be of the size and number required to remove oversize aggregate and to
    separate the materials into two or more fractions so that they may be combined to meet the
    required gradation.

    3 A central mixing plant shall be used for the mixing of materials.

    4 Mixing of separate materials on the roadway by motor grader will not be permitted.

    4.6 SPREADING AND COMPACTION

    1 Before commencing the construction of the Subbase and Road Base courses, a written
    approval for the Engineer must be obtained that the subgrade is in compliance.

    2 The optimum moisture content of the material shall be noted from the mix design and the
    actual moisture content determined at the plant after mixing.

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    3 If the natural moisture content is less than the optimum moisture content, the necessary

    rw
    amount of water must be added to obtain the optimum content.

    4 Allowance shall be made for the quantity of moisture which may be lost by evaporation in the

    ta
    process of raking, levelling and compacting, depending on atmospheric temperature.
    qa
    5 The compacted layer shall have moisture content within 1.5% of the optimum moisture
    content for Road Base layers and within 2% for Subbase layers.
    as

    6 The moisture content shall be uniform in all parts of the section where the work is being
    se

    carried out and in the various depths of the layer thickness.


    er

    7 Subbase and Road Base courses shall be laid by a paving machine with a spreader box.
    ov

    8 Loose samples of materials for testing and acceptance shall be obtained from behind the
    paving machine upon the approval of the Engineer.
    it o

    9 Compaction shall start immediately the material has been laid and as per the approved rolling
    et

    pattern.
    m

    10 Work on the Subbase and Road Base courses shall not be permitted during rainy weather.

    11 Material shall be spread to a thickness that would result in layers not more than 150 mm thick
    after compaction. Where the finished compacted thickness exceeds 150 mm placing shall
    be executed in composite layers each layer not exceeding 150 mm in compacted thickness
    as directed by the Engineer.

    12 The course shall not be rolled when the underlying material is soft or yielding or when the
    rolling causes a wave-like motion in this course.

    13 When the rolling develops irregularities, the irregular surface shall be loosened, then refilled
    with the same kind of material as used in constructing the course and again rolled.

    14 Along places inaccessible to rollers, the Subbase and Road Base courses material shall be
    tamped thoroughly with suitable mechanical tampers to achieve the required density and
    finish.
    QCS 2014 Section 06: Roadworks Page 11
    Part 04: Unbound Pavement Materials

    15 Rolling must continue until a relative density of not less than 100 % of the maximum dry
    density has been obtained as determined by the moisture-density relationship in ASTM
    D1557.

    16 Care shall be taken so that layers already compacted under the layer being executed are not
    damaged, or that the formation is not damaged.

    17 This aspect must be given special attention in places where rolling equipment makes turns to
    change direction.

    18 Any such damage resulting in mixing the various layers constituting the different subgrades,
    Subbase and Road Base courses shall be carefully made good by the Contractor at his own
    expense and to the satisfaction of the Engineer.

    .
    4.7 CORRECTIVE ACTION

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    1 Any material that fails to meet test requirements shall either be reworked or removed and

    rw
    replaced and then retested to check for compliance.

    2
    ta
    Any soft spots, irregularities or depressions that develop in the surface of the Subbase or
    Road Base courses, shall either be corrected by loosening the surface of such areas and
    qa
    adding further material, or by removing the material in such areas and replacing with further
    approved material.
    as

    3 In the event of heave occurring during compaction, caused either by excessive build-up of
    pore water pressure or the groundwater table being sufficiently high to affect construction
    se

    techniques, either of the following procedures shall be adopted subject to the approval of the
    Engineer:
    er

    (a) Sufficient time shall be allowed to elapse enabling the excess pore water to dissipate
    ov

    before further construction or compaction is carried out


    (b) The affected material shall be removed, and approved alternative construction layers
    o

    substituted.
    it

    4 For correction of low density or incorrect level, the top 75 mm shall be scarified, reshaped
    et

    with material added or removed as necessary and re-compacted to the designated


    m

    requirement. The area treated shall not be less than 30 metres long and 2 metres wide or
    such area determined by the Engineer as necessary to attain compliance.

    5 Where the surface of the sub-base is covered in a very thin smooth skin composed of fine
    particles cemented together acting as a barrier to the prime coat the top 75 mm shall be
    scarified, reshaped, watered if necessary, and re-compacted prior to the application of prime
    coat.

    6 The Contractor shall carry out additional testing if required by the Engineer to ensure that the
    standard of compaction is satisfactory through the full depth of the layer.

    4.8 PROTECTION OF SURFACE

    1 The Contractor shall protect the Subbase and Road Base courses so that it shall be
    maintained sound during work progress, after its completion and before receiving the
    bituminous layers or before laying the surface overlay thereon.
    QCS 2014 Section 06: Roadworks Page 12
    Part 04: Unbound Pavement Materials

    2 Any damage caused to the layer if exposed to traffic or natural conditions resulting in damage
    to its surface shall be made good at the expense of the Contractor and to the satisfaction of
    the Engineer.

    3 The Engineer has the right to stop all hauling over completed or partially completed Subbase
    and Road Base courses when in his opinion such hauling is causing damage.

    4 Following the completion of the Subbase or Road Base courses the Contractor shall perform
    all maintenance work necessary to keep the course in a condition for priming.

    4.9 TESTING

    4.9.1 General

    1 Loose materials for testing and acceptance shall be sampled from the un-compacted in-place

    l .
    layer.

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    2 All testing shall be conducted in accordance with ASTM, AASHTO and BS standards listed in
    section 4.2.

    3
    ta
    Testing frequency for the properties of Subbase or Road Base layers are listed in Tables 4.1,
    qa
    4.2 and 4.3.

    4 At any stage in the mixing, transportation, spreading or compaction process, the Engineer
    as

    may instruct that these tests are carried out.


    se

    5 Before the application of any prime coat or any other paving course, the aggregate Subbase
    or Road Base courses shall have been tested for compliance with the requirements of this
    er

    clause on testing and approved by the Engineer.


    ov

    4.9.2 Thickness

    1 The thickness of the material shall be derived from checking the level by dipping from string
    o

    lines stretched across the roadway between pins or kerbs. Unless agreed otherwise with the
    it

    Engineer dipping shall be carried out at intervals of not less than 10m.
    et

    2 The thickness of the material shall be measured at the location where the material is
    m

    removed from the roadway for gradation analysis.

    3 Wherever the thickness of compacted aggregate Subbase or Road Base courses is found to
    vary from the thickness specified in the project drawings or specification by more than 10 %
    the area involved shall be satisfactorily corrected to provide the required thickness
    constructed to the designated grade level.

    4.9.3 Evenness and Level

    1 The final surfaces of the Subbase or Road Base courses shall be tested by means of a 3
    meter long straight edge in accordance with ASTM E1703 and no rises or depressions in
    excess of 10 mm shall appear in the surface. Measurements shall be carried out at
    maximum spacing of 30m of road length for each lane.
    QCS 2014 Section 06: Roadworks Page 13
    Part 04: Unbound Pavement Materials

    2 The finished surface shall also be checked by dips or spot levels and shall be constructed to
    the designated grade levels to within 10 mm.

    3 Where these requirements are not met, the Contractor shall determine the full extent of the
    area which is out of tolerance and shall make good the surface of the course by scarifying to
    a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater,
    reshaping by adding or removing material as necessary, adding water if necessary and re-
    compacting.

    END OF PART

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    as
    se
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    et
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    QCS 2014 Section 06: Roadworks Page 1
    Part 05: Asphalt Works

    5 ASPHALT WORKS.................................................................................................. 3
    5.1 GENERAL ............................................................................................................... 3
    5.1.1 Scope 3
    5.1.2 References 3
    5.1.3 Definitions 7
    5.1.4 Submittals 7
    5.1.5 Quality Assurance 8
    5.2 MATERIALS ............................................................................................................ 8
    5.2.1 Unacceptable Materials 8
    5.2.2 Fine Aggregate 9
    5.2.3 Coarse Aggregate 9
    5.2.4 Recycled Aggregate 10

    .
    5.2.5 Mineral Filler 10

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    5.2.6 Asphalt Binder 11
    5.2.7 Prime Coat 13

    rw
    5.2.8 Tack Coat 13
    5.2.9 Delivery, Storage and Handling 13
    5.2.10 Inspection and Control
    ta 14
    qa
    5.3 MARSHALL MIX DESIGN ..................................................................................... 14
    5.3.1 General 14
    5.3.2 Marshall Mix Design Criteria 15
    as

    5.3.3 Quality Control Testing 17


    se

    5.4 DENSE BITUMEN MACADAM .............................................................................. 20


    5.5 SUPERPAVE MIX DESIGN ................................................................................... 22
    er

    5.6 PERFORMANCE EVALUATION OF ASPHALT CONCRETE ................................ 24


    ov

    5.7 DELIVERY, SPREADING AND FINISHING ........................................................... 25


    5.7.1 Delivery of Mixes 25
    o

    5.7.2 Spreading and Finishing 25


    it

    5.7.3 Compaction of Mixes 26


    et

    5.7.4 Transverse Joints 27


    5.7.5 Longitudinal Joints 28
    m

    5.7.6 Paving Edges 28


    5.7.7 Breakdown Rolling 28
    5.7.8 Intermediate Rolling 29
    5.7.9 Finish Rolling 29
    5.7.10 Protection of Laid Courses 29
    5.8 COLD PLANING .................................................................................................... 29
    5.9 PRIME COAT ........................................................................................................ 30
    5.9.1 General 30
    5.9.2 Equipment Required 30
    5.9.3 Surface Preparation 30
    5.9.4 Application 30
    5.9.5 Maintenance and Traffic 31
    QCS 2014 Section 06: Roadworks Page 2
    Part 05: Asphalt Works

    5.10 TACK COAT .......................................................................................................... 31


    5.10.1 General 31
    5.10.2 Equipment Required 31
    5.10.3 Surface Preparation 32
    5.10.4 Application 32
    5.10.5 Maintenance and Traffic 32
    5.11 THICKNESS AND LEVEL...................................................................................... 32
    5.11.1 Thickness 32
    5.11.2 Transverse Evenness 33
    5.11.3 Evenness and Rideability 33
    5.12 PAVEMENT EVALUATION TECHNIQUES ........................................................... 35
    5.13 PRODUCTION OF ASPHALT CONCRETE COURSES ........................................ 35

    .
    5.13.1 Weather Limitations 35

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    5.13.2 Equipment Required 35
    5.13.3 Survey and Preparation 35

    rw
    5.13.4 Heating of Asphalt Binder 36
    5.13.5 Heating of Mineral Aggregate 36
    5.13.6 Proportioning and Mixing
    ta 36
    qa
    5.14 HAULING EQUIPMENT......................................................................................... 37
    5.15 OTHER EQUIPMENT ............................................................................................ 37
    as

    5.15.1 Spreading and Finishing Equipment 37


    5.15.2 Rolling Equipment 38
    se

    5.15.3 Liquid Asphalt Distributor 39


    APPENDIX .......................................................................................................................... 40
    er
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    QCS 2014 Section 06: Roadworks Page 3
    Part 05: Asphalt Works

    5 ASPHALT WORKS

    5.1 GENERAL

    5.1.1 Scope

    1 Materials, equipment, and construction of bituminous paving works including prime coating
    and tack coating.

    2 Related Parts

    Part 1, ............. General


    Part 3, ............. Earthworks
    Part 4, ............. Unbound Pavement Materials.

    l .
    5.1.2 References

    .l.
    rw
    1 The following standards and other documents are referred to in this Part:

    ta
    ASTM C40 ..................Standard Test Method for Organic Impurities in Fine Aggregates for
    Concrete
    qa
    ASTM C50 ..................Standard Practice for Sampling, Sample Preparation, Packing and
    Marking of Lime and Limestone Products
    as

    ASTM C51 ..................Terminology Relating to Lime and Limestone (as used by the industry)
    ASTM C88 .................Standard Test Method for Soundness of Aggregates by Use of Sodium
    se

    Sulphate or Magnesium Sulphate


    ASTM C117 ................Standard Test Method for Materials Finer than 75-m (No. 200) Sieve
    er

    in Mineral Aggregates by Washing


    ov

    ASTM C127 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
    and Absorption of Coarse Aggregate
    o

    ASTM C128 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
    and Absorption of Fine Aggregate
    it
    et

    ASTM C131 ...............Standard Test Method for Resistance to Degradation of Small Size
    Coarse Aggregate by Abrasion and Impact in the Los Angeles
    m

    Machine
    ASTM C136 ...............Standard Test Method for Sieve Analysis of Fine and Coarse
    Aggregates
    ASTM C142 ...............Standard Test Method for Clay Lumps and Friable Particles in
    Aggregates
    ASTM C150 ................Specifications for Portland Cement
    ASTM C535 ...............Standard Test Method for Resistance to Degradation of Large Size
    Coarse Aggregate by Abrasion and Impact in the Los Angeles
    Machine
    ASTM D5 ....................Standard Test Method for Penetration of Bituminous Materials
    ASTM D6 ....................Standard Test Method for Loss on Heating of Oil and Asphaltic
    Compounds
    ASTM D36 ..................Standard Test Method for Softening Point of Bitumen (Ring-and-Ball
    Apparatus)
    QCS 2014 Section 06: Roadworks Page 4
    Part 05: Asphalt Works

    ASTM D75 .................Standard Practice for Sampling Aggregates


    ASTM D92 .................Standard Test Method for Flash and Fire Points by Cleveland Open
    Cup Tester
    ASTM D113 ................Standard Test Method for Ductility of Bituminous Materials
    ASTM D140 ...............Standard Practice for Sampling Bituminous Materials
    ASTM D242 ................Standard Specification for Mineral Filler for Bituminous Paving
    Mixtures
    ASTM D402 ................Standard Test Method for Distillation of Cutback Asphaltic
    (Bituminous) Products
    ASTM D546 ................Standard Test Method for Sieve Analysis of Mineral Filler for
    Bituminous Paving Mixtures
    ASTM D946 ...............Standard Specification for Penetration Graded Asphalt Cement for
    Use in Pavement Construction

    l .
    ASTM D977 ................Standard Specification for Emulsified Asphalt

    .l.
    ASTM D979 ................Standard Practice for Sampling Bituminous Paving Mixtures

    rw
    ASTM D995-95...........Standard Specification for Mixing Plants for Hot-Mixed, Hot-Laid
    Bituminous Paving Mixtures

    ta
    ASTM D1188: ............Standard Test Method for Bulk Specific Gravity and Density of
    Compacted Bituminous Mixtures Using Coated Samples
    qa
    ASTM D2027 ..............Standard Specification for Cutback Asphalt (Medium-Curing Type)
    ASTM D2041 .............Standard Test Method for Theoretical Maximum Specific Gravity and
    as

    Density of Bituminous Paving Mixtures


    ASTM D2042 ..............Standard Test Method for Solubility of Asphalt Materials in
    se

    Trichloroethylene
    ASTM D2172 .............Standard Test Methods for Quantitative Extraction of Bitumen from
    er

    Bituminous Paving Mixtures


    ov

    ASTM D2419 .............Standard Test Method for Sand Equivalent Value of Soils and Fine
    Aggregate
    o

    ASTM D2726 .............Standard Test Method for Bulk Specific Gravity and Density of Non
    it

    Absorptive Compacted Bituminous Mixtures


    et

    ASTM D2872 .............. Standard Test Method for Effect of Heat and Air on a Moving Film of
    Asphalt (Rolling Thin Film Oven Test)
    m

    ASTM D2950 ..............Standard Test Method for Density of Bituminous Concrete in Place by
    Nuclear Methods
    ASTM D2995 ..............Standard Practice for Estimating Application Rate of Bituminous
    Distributors
    ASTM D3319 ..............Standard Practice for the Accelerated Polishing of Aggregates Using
    the British Wheel
    ASTM D3549 ..............Standard Test Method for Thickness or Height of Compacted
    Bituminous Paving Mixture Specimens
    ASTM D4318 .............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
    Index of Soils
    ASTM D4402 .............Standard Test Method for Viscosity Determination of Asphalt at
    Elevated Temperatures Using a Rotational Viscometer
    ASTM D4791 .............Standard Test Method for Flat Particles, Elongated Particles, or Flat
    and Elongated Particles in Coarse Aggregate
    QCS 2014 Section 06: Roadworks Page 5
    Part 05: Asphalt Works

    ASTM D5361 ..............Standard Practice for Sampling Compacted Bituminous Mixtures for
    Laboratory Testing
    ASTM D5444 ..............Standard Test Method for Mechanical Size Analysis of Extracted
    Aggregate
    ASTM D5546 .............Standard Test Method for Solubility of Asphalt Binders in Toluene by
    Centrifuge
    ASTM D5581 ..............Standard Test Method for Resistance to Plastic Flow of Bituminous
    Mixtures Using Marshall Apparatus (6 inch-Diameter Specimen)
    ASTM D5821 .............Standard Test Method for Determining the Percentage of Fractured
    Particles in Coarse Aggregate
    ASTM D6307 ..............Standard Test Method for Asphalt Content of Hot-Mix Asphalt by
    Ignition Method
    ASTM D6373 ..............Standard Specification for Performance Graded Asphalt Binder

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    ASTM D6521 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a

    .l.
    Pressurized Aging Vessel (PAV)

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    ASTM D6648 .............Standard Test Method for Determining the Flexural Creep Stiffness of
    Asphalt Binder Using the Bending Beam Rheometer (BBR)

    ta
    ASTM D6723 ..............Standard Test Method for Determining the Fracture Properties of
    Asphalt Binder in Direct Tension (DT)
    qa
    ASTM D6926 .............Standard Practice for Preparation of Bituminous Specimens Using
    Marshall Apparatus
    as

    ASTM D6927 ..............Standard Test Method for Marshall Stability and Flow of Bituminous
    Mixtures
    se

    ASTM D6931 ..............Standard Test Method for Indirect Tensile (IDT) Strength of
    Bituminous Mixtures
    er

    ASTM D7173 .............Standard Practice for Determining the Separation Tendency of


    Polymer from Polymer Modified Asphalt
    ov

    ASTM D7175 .............Standard Test Method for Determining the Rheological Properties of
    Asphalt Binder Using a Dynamic Shear Rheometer
    o

    ASTM D7405 .............Standard Test Method for Multiple Stress Creep and Recovery
    it

    (MSCR) of Asphalt Binder Using a Dynamic Shear Rheometer


    et

    ASTM E11 .................Standard Specification for Woven Wire Test Sieve Cloth and Test
    m

    Sieves
    ASTM E274 ................Standard Test Method for Skid Resistance of Paved Surfaces Using a
    Full-Scale Tire
    ASTM E303 ................Standard Test Method for Measuring Surface Frictional Properties
    Using the British Pendulum Tester
    ASTM E950................. Standard Test Method for Measuring the Longitudinal Profile of
    Travelled Surfaces with an Accelerometer Established Inertial Profiling
    Reference
    ASTM E965 ................Standard Test Method for Measuring Pavement Macrotexture Depth
    Using a Volumetric Technique
    ASTM E1926............... Standard Practice for Computing International Roughness Index of
    Roads from Longitudinal Profile Measurements

    AASHTO M82.............Standard Specification for Cutback Asphalt (Medium-Curing Type)


    QCS 2014 Section 06: Roadworks Page 6
    Part 05: Asphalt Works

    AASHTO M92.............Standard Specification for Wire-Cloth Sieves for Testing Purposes

    AASHTO M140...........Standard Specification for Emulsified Asphalt


    AASHTO M208...........Standard Specification for Cationic Emulsified Asphalt (ASTM D2397-
    02)
    AASHTO M320...........Standard Specification for Performance-Graded Asphalt Binder
    AASHTO M332...........Standard Specification for Performance-Graded Asphalt Binder Using
    Multiple Stress Creep Recovery (MSCR) Test, Single User Digital
    Publication
    AASHTO R28 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a
    Pressurized Aging Vessel (PAV)
    AASHTO R35 ............ Standard Practice for Superpave Volumetric Design for Hot-Mix Asphalt
    (HMA)

    l .
    AASHTO T44 .............Standard Method of Test for Solubility of Bituminous Materials

    .l.
    AASHTO T48 .............Standard Method of Test for Flash and Fire Points by Cleveland Open

    rw
    Cup
    AASHTO T240 ...........Standard Method of Test for Effect of Heat and Air on a Moving Film of

    ta
    Asphalt Binder (Rolling Thin-Film Oven Test)
    AASHTO T313 ...........Standard Method of Test for Determining the Flexural Creep Stiffness
    qa
    of Asphalt Binder Using the Bending Beam Rheometer (BBR)
    AASHTO T283 ........... Standard Method of Test for Resistance of Compacted Asphalt Mixtures
    as

    to Moisture-Induced Damage
    AASHTO T314 ...........Standard Method of Test for Determining the Fracture Properties of
    se

    Asphalt Binder in Direct Tension (DT)


    AASHTO T315 ...........Standard Method of Test for Determining the Rheological Properties of
    er

    Asphalt Binder Using a Dynamic Shear Rheometer (DSR)


    ov

    AASHTO T316 ...........Standard Method of Test for Viscosity Determination of Asphalt Binder
    Using Rotational Viscometer
    AASHTO T350 ...........Standard Method of Test for Multiple Stress Creep Recovery (MSCR)
    o

    Test of Asphalt Binder Using a Dynamic Shear Rheometer (DSR)


    it
    et

    AASHTO PP60 ........... Standard Practice for Preparation of Cylindrical Performance Test
    Specimens Using the Superpave Gyratory Compactor (SGC)
    m

    AASHTO PP61 .......... Standard Practice for Developing Dynamic Modulus Master Curves for
    Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester
    (AMPT)
    AASHTO TP79 .......... Standard Method of Test for Determining the Dynamic Modulus and
    Flow Number for Hot Mix Asphalt (HMA) Using the Asphalt Mixture
    Performance Tester (AMPT)

    BS 812-110 ................Testing aggregates Methods for determination of aggregate crushing


    value (ACV)
    BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and
    electro-chemical tests
    BS EN 12697-13 ........Bituminous mixtures. Test methods for hot mix asphalt. Temperature
    measurement
    QCS 2014 Section 06: Roadworks Page 7
    Part 05: Asphalt Works

    5.1.3 Definitions

    1 LSA: Laboratories and Standardization Affairs Ministry of Environment.

    2 Base Course: One or more bituminous layers beneath Wearing Course and above the
    unbound Road Base Layer. It usually consists of a mixture of aggregates and bituminous
    materials and functions as a structural portion of pavement.

    3 Wearing Course: Top surface bituminous course, which resists skidding, traffic abrasion, and
    the disintegrating effects of climate.

    5.1.4 Submittals

    1 The Contractor shall submit for approval a proposed Job Mix Formula (JMF) together with all
    applicable design data at least one month before beginning the work. The JMF shall give a

    l .
    combined gradation showing a single definite percentage passing each sieve as well as a

    .l.
    percentage of each material to be used in the mix. The JMF shall also establish the mixing

    rw
    and compaction temperature values and a compaction reference density. The Engineer will
    test samples of the materials proposed for use in order to check their quality and to check the
    proposed mix design. The Contractor shall report all the values obtained in the laboratory

    ta
    design and shall submit these together with a copy of the plotted curves resulting from the
    qa
    tests in an approved form to the Engineer. The Engineer may require verification of the
    submitted design before giving approval. The Engineer shall approve the optimum binder
    content based upon the design values submitted by the Contractor and shall notify the
    as

    Contractor of the value. No asphalt works will be allowed to commence before the
    Contractor receives written approval from the Engineer for his JMF.
    se

    2 The asphalt mix design submission shall include a copy of valid calibration certificates from a
    er

    calibration service agency approved by the Laboratories and Standardization Affairs (LSA) for
    the batching plant and the relevant laboratory equipment such as but not limited to balances,
    ov

    proving rings, and load devices. Approval certificates for mix designs will not be issued if the
    above requirements have not been complied with.
    o

    3 Based on the Engineer request, the Contractor shall submit the pertinent certifications of
    it

    materials, equipment, plants, personnel and processes in relation to the project. Certificates
    et

    must be issued by a competent authority approved by the Engineer.


    m

    4 The contractor shall submit to the Engineer for approval method statements for the following:

    (a) Bituminous and asphalt materials production, storage, transportation, identification and
    marking procedure and traceability to source of production.
    (b) Quality assurance and quality control plans for laying, compaction and all construction
    activities.
    (c) Quality control testing plan.
    (d) Equipment and its suitability to fulfil all construction activities to the required quality.
    (e) Personnel capability.
    (f) Safety and environment preservation measures.

    5 The Contractor shall provide the Engineer with a complete report on the origin and
    composition of all stone and/or gravel aggregates to be used in the work (Aggregate
    Resources Report). All materials shall comply with the specified requirements for the various
    aggregates.
    QCS 2014 Section 06: Roadworks Page 8
    Part 05: Asphalt Works

    6 Delivery of materials produced from commercial manufacturing process shall be


    accompanied by the manufacturers certification and test reports from local approved
    laboratory showing the materials compliance with the specification for which it is stipulated.

    7 After receiving the approval of specific sources of material the Contractor cannot change
    these sources without prior written approval of the Engineer.

    5.1.5 Quality Assurance

    1 The Contractor shall notify the Engineer of the sources of materials and the Engineer shall
    approve the sources. All materials shall be tested and approved before use.

    2 Where the quality of material from a source of material does not comply with the designated
    requirements, the Contractor shall furnish material that does comply from other sources.
    Delivery of materials produced from commercial manufacturing processes shall be

    .
    accompanied by the manufacturer's certification and test report showing that the materials

    l
    .l.
    comply with the designated requirements.

    rw
    3 No change shall be permitted in the source of any of the materials until the technical
    submissions listed in the specification have been made and approved by the Engineer.

    4
    ta
    All processed materials shall be tested and approved before being stored at the site or
    qa
    incorporated in the works and may be inspected and tested at any time during the progress
    of their preparation and use. Questionable materials, pending laboratory testing subsequent
    approval shall not be unloaded and incorporated with materials previously approved and
    as

    accepted.
    se

    5 It is the full responsibility of both the asphalt mixture producer and the Contractor to obtain a
    certificate which proves that the asphalt binder complies with the specifications. Furthermore,
    er

    both the asphalt mixture producer and the Contractor shall perform all the required tests in an
    approved private laboratory to make sure that the asphalt binder being purchased complies
    ov

    with the specifications. The LSA will, at any time, take samples from the asphalt mixtures
    producers plants and test them as part of its quality practice.
    it o

    5.2 MATERIALS
    et

    5.2.1 Unacceptable Materials


    m

    1 Materials that do not conform to the designated requirements shall be rejected and
    immediately removed from the site of the works unless otherwise instructed by the Engineer.
    No rejected material, the defects of which have been corrected, shall be used until approval
    has been given by the Engineer.

    2 Bituminous paving courses shall consist of coarse aggregate, fine aggregate, filler material,
    and bitumen binder. Mixture of two different types of rocks, e.g. igneous and sedimentary
    having different engineering properties shall not be permitted.

    3 During execution of works, variations in the specific gravity of any individual fraction of
    aggregates used in the asphalt mixes by more than 1% shall cause the Engineer to request
    for evaluation of aggregates consistency and compliance and/or mix design validation.
    QCS 2014 Section 06: Roadworks Page 9
    Part 05: Asphalt Works

    5.2.2 Fine Aggregate

    1 Fine aggregate is that portion of the mineral aggregate passing the 2.36mm ASTM sieve for
    the Marshall mix design and passing the 4.75mm sieve for the Superpave mix design.

    2 Fine aggregate shall consist of crushed hard durable rock and shall be of such gradation that
    when combined with other aggregates in proper proportions, the resultant mixture will meet
    the required gradation. Fine aggregate shall be non-plastic and chemically stable.

    3 The source of natural fine aggregate is considered to be the crusher site at which it is
    produced. Crushed fine aggregate shall be produced by crushing clean coarse aggregate
    and shall not be thin, flaky or elongated. Sampling of fine aggregate shall be in accordance
    with ASTM D75.

    4 Fine aggregate shall be clean and free from organic matter, clay, cemented particles and

    l .
    other extraneous or detrimental materials.

    .l.
    rw
    5 Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
    Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

    6
    ta
    The Contractor shall ensure that the sources of all fine aggregates have been approved by
    the Municipality concerned.
    qa
    7 The specifications of fine aggregates for asphalt mixtures are listed in Table 5.1.
    as

    Table 5.1
    Fine Aggregate Specifications for Marshall Mixes
    se

    Parameter Standard Specification Limits Minimum Frequency


    er

    4% max. (stockpile)
    Plasticity index ASTM D 4318
    ov

    Non Plastic (hot bins)


    Sand equivalent value ASTM D2419 45% min. - Each source
    o

    Soundness by magnesium
    ASTM C88 18% max. - Visible change in
    sulphate
    it

    material
    et

    Acid soluble chloride content BS 1377 Part 3 0.1% max. 3


    - 1 test every 2000m
    Acid soluble sulphate content BS 1377 Part 3 0.5% max.
    m

    Clay lumps and friable particles ASTM C142 None


    Organic Impurities ASTM C40 No Impurities

    5.2.3 Coarse Aggregate

    1 Coarse aggregate is that portion of the mineral aggregate retained on the 2.36mm ASTM
    sieve for the Marshall mix design and retained on the 4.75mm ASTM sieve for the
    Superpave mix design. Coarse aggregate shall consist of crushed natural stones and gravel.
    Crushed particles shall be cubic and angular in shape and shall not be thin, flaky or
    elongated. The gradation shall be such that when combined with other aggregate fraction in
    proper proportions, the resultant mixture will meet the required gradation.

    2 The source of crushed aggregate is considered to be the crushing site from which it is
    produced. Sampling of coarse aggregate shall be in accordance with ASTM D75.
    QCS 2014 Section 06: Roadworks Page 10
    Part 05: Asphalt Works

    3 Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and
    other extraneous or detrimental material.

    4 The specifications of coarse and combined aggregates for asphalt mixtures are listed in
    Table 5.2.

    5 Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
    Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.

    6 If directed by the Engineer, the polished stone value (PSV) should be determined for wearing
    course aggregates of main lane as per ASTM D3319. The PSV shall not be less than 45.

    5.2.4 Recycled Aggregate

    1 Recycled aggregate produced from excavating natural ground can be used in asphalt

    l .
    mixtures for temporary roads and for roads, which serve agricultural areas provided that the

    .l.
    specifications stated in Section 6 - Part 9 are complied.

    rw
    Table 5.2
    Coarse and Combined Aggregate Specifications for Marshall Mixes

    Parameter Standard ta
    Specification Limits
    Base Course Base Course Wearing
    Minimum
    qa
    Frequency
    (Class A) (Class B) Course
    One or more Fractured
    ASTM D5821 100% min. 100% min. 100% min.
    as

    Faces
    1
    Two or more Fractured
    ASTM D5821 85% min. 85% min. 85% min.
    Faces
    se

    Table 5.7, Job Mix gradation and Table


    Gradation (Combined) ASTM C136 - Each source
    5.10 tolerances
    er

    Flat and Elongated - Visible change


    ASTM D4791 15 % max. 15% max. 10 % max.
    Particles (5:1) in material
    ov

    Soundness
    ASTM C88 15 % max. 15% max. 10 % max. - 1 test every
    (5 cycles by MgSO4) 3
    2000m
    o

    ASTM C131
    Los Angeles Abrasion 30% max. 30% max. 25% max.
    ASTM C535
    it

    Water absorption ASTM C127 2.0% max. 2.0% max. 1.5% max.
    et

    Aggregate Crushing BS 812


    25 % max. 25 % max. 20% max.
    m

    Value (ACV) Part 110


    1
    Higher values can be recommended by the engineer based on the design ESAL.
    5.2.5 Mineral Filler

    1 Mineral filler when separately supplied from an external source shall consist of finely ground
    mineral matter in accordance with ASTM D242 such as rock dust, hydrated lime, cement or
    other material which can satisfy the Engineer will produce asphalt mixes of at least equal
    quality. It shall be free from organic substances and clay, shall be thoroughly dry and free
    from agglomerations, shall be non-plastic and shall meet the grading requirements shown in
    Table 5.3.

    2 Hydrated lime shall conform to the definitions given in ASTM C51. Sampling, packaging and
    marking of hydrated lime shall be in accordance with ASTM C50. Storage and use of the
    hydrated lime shall at all times be such as to protect the material from the weather.
    QCS 2014 Section 06: Roadworks Page 11
    Part 05: Asphalt Works

    Table 5.3
    ASTM Sieve % Mass Passing
    600 m 100
    300 m 95 - 100
    150 m 90 100
    75 m 70 100
    3 The grading of mineral filler shall be carried out in accordance with ASTM D546.

    4 When cement is used as mineral filler, it shall meet the requirements of ASTM C150.

    5.2.6 Asphalt Binder

    .
    1 The asphalt binder specified for use in the asphalt mixes shall be either of the following:

    l
    .l.
    (a) Penetration grade 60-70: This binder type shall be graded in accordance with ASTM

    rw
    D946. The 60-70 binder specifications are listed in Table 5.4. Sampling shall be in
    accordance with ASTM D140. The 60-70 penetration graded binder is generally
    equivalent to PG 64-10 performance graded binder.
    (b) ta
    PG 76-10: Based on the Engineer approval, the PG76-10 binder can be used in
    qa
    asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting
    AASHTO M320 and ASTM D6373 specifications in addition to separation test criteria
    as listed in Table 5.5. Sampling shall be in accordance with ASTM D140.
    as

    2 Prior to the commencement of the mix design, the Contractor shall provide a certificate
    indicating conformance of binder with the specifications stated above. This certificate shall be
    se

    obtained from an approved laboratory.


    er

    3 The asphalt binder shall be prepared by the refining of petroleum and shall be uniform in
    ov

    character. Blending of asphalt binders from different refineries will be permitted only with the
    written approval of the Engineer.
    Table 5.4
    o

    Specifications of Bitumen Penetration Grade 60 70


    it

    60 70 Pen
    et

    Parameter Standard Minimum Frequency


    Min. Max.
    m

    Penetration (0.1 mm) at 25C - Each source


    ASTM D5 60 70
    -100g, 5 Sec
    - Visible change in material
    Softening Point Ring & Ball
    ASTM D36 46 - - 1 test per 75t of asphalt
    Apparatus, C binder per layer
    Flash Point, Cleveland Open
    ASTM D92 230 -
    Cup, C
    Ductility at 25 C, cm ASTM D113 100 - - Each source
    Solubility Trichloroethylene, % ASTM D2042 99 -
    - Visible change in material
    Loss on heating, % ASTM D6 - 0.2
    Penetration of Residue of - 1 test per 450t of asphalt
    ASTM D5 52 -
    original after TFOT, % binder per layer
    Ductility of Residue after
    ASTM D113 50 -
    TFOT at 25 C, 5cm/min, cm
    QCS 2014 Section 06: Roadworks Page 12
    Part 05: Asphalt Works

    Table 5.5
    Specifications of Performance Graded Binders / Polymer Modified Binders (PMB)

    Standard Minimum
    Parameter Specification
    AASHTO ASTM Frequency
    Tests on Original Binder
    Average 7 days maximum pavement
    o - - < 76
    design temperature, ( C)
    Minimum pavement design - - - Each source
    o >-10
    temperature,( C)
    o
    - Visible change in
    Flash Point Temperature, Minimum ( C) T48 D92 230 material
    Rotational Viscosity, Maximum 3 Pa.s,
    o T316 D4402 135 - 1 test per 450t of
    Test Temperature ( C)
    asphalt binder per
    Dynamic Shear, G*/sin, Minimum, 1.00
    T315 D7175 76 layer

    .
    o
    kPa , Test Temperature ( C) at 10 rad/s

    l
    .l.
    Solubility, min, % T44 D5546 99
    1

    rw
    Separation Test: Absolute Difference
    o
    between G* @ 76 C and 10 rad/s of Top - D7173 20
    and Bottom Specimens, Maximum, %

    ta
    Requirements of the Rolling Thin Film Oven Residue ( T240 / D2872)
    qa
    Mass Loss, Maximum, Percent T240 D2872 1
    Dynamic Shear, G*/sin, Minimum, 2.20
    o T315 D7175 76
    kPa , Test Temperature ( C) at 10 rad/s
    - Each source
    as

    Pressure Aging Vessel Residue (D6521 / R28)


    PAV Aging Temperature , ( C)
    o
    R28 D6521 110 - Visible change in
    se

    Dynamic Shear, G*.sin, Maximum 5000 material


    o T315 D7175 37
    kPa , Test Temperature ( C) at 10 rad/s - 1 test per 450t of
    er

    Creep Stiffness, S, Maximum 300 MPa asphalt binder per


    and m-value, Minimum 0.300 at 60 T313 D6648 0 layer
    ov

    o
    seconds , Test Temperature ( C)
    2
    Direct Tension , Failure Strain, Minimum,
    o

    1.0% (loading rate of 1.0 mm/min),Test T314 D6723 0


    it

    o
    Temperature( C)
    et

    1
    Absolute Difference = Abs(100x(top-bottom)/top).
    2
    If the creep stiffness is below 300 MPa, the direct tension test is not required. If the creep stiffness is
    m

    between 300 and 600 MPa, the direct tension failure strain requirement can be used in lieu of the creep
    stiffness requirement. The m-value requirement must be satisfied both cases.

    4 Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
    heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
    AASHTO M332 and will be required to indicate elastic response in percent recovery when
    tested in accordance with AASHTO T350 / ASTM D7405.

    5 Binders modified using Crumb Rubber and other binders containing particulate materials,
    which are graded according to AASHTO M320 and/or AASHTO M332, shall not include
    particles with longest dimensions of more than 250m. In addition, the requirements listed in
    Table 5.5 shall be satisfied.
    QCS 2014 Section 06: Roadworks Page 13
    Part 05: Asphalt Works

    5.2.7 Prime Coat

    1 Liquid asphalt for use as prime coat shall be MC-70 medium curing cutback asphalt in
    accordance with ASTM D2027 or AASHTO M82.

    2 The prime coat shall be a cutback consisting of a 60/70 penetration grade bitumen and
    kerosene. The residue from the distillation test, carried out to 360 C in accordance with
    ASTM D402, shall be a minimum of 55 % (by volume), as determined by the difference
    method. Sampling shall be in accordance with ASTM D140. One sample shall be tested
    every 5 tons.

    5.2.8 Tack Coat

    1 Emulsified asphalt for use as tack coat in asphalt works may be CSS 1h or CRS-2 cationic
    emulsified asphalt in accordance with AASHTO M 208 or SS 1h anionic emulsified asphalt in

    l .
    accordance with ASTM D977 or AASHTO M140 unless otherwise designated.

    .l.
    rw
    2 Emulsified asphalt shall be of the slow-setting cationic or anionic type of the CSS-1h or SS-
    1h grades respectively and shall conform to the designated requirements. Sampling shall be
    in accordance with ASTM D140. One sample shall be tested every 5 tons.

    ta
    qa
    5.2.9 Delivery, Storage and Handling

    1 Materials shall be so stored and handled as to assure the preservation of their quality and
    as

    fitness for use. Materials, even though approved before storage or handling, may again be
    inspected and tested before use in the Works.
    se

    2 Stored material shall be located so as to facilitate their prompt inspection. All storage
    er

    locations on land not owned by the Contractor shall be restored to their original condition at
    the Contractor's expense.
    ov

    3 Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
    or contamination of the various sizes and to prevent contamination of materials by dust.
    o

    Stockpiles shall be kept flat and the formation of high cone-shaped piles shall not be
    it

    permitted. When conveyor belts are used for stockpiling aggregates, the Engineer may
    et

    require the use of baffle-chutes or perforated chimneys.


    m

    4 Where trucks are used to construct stockpiles, the stockpiles shall be constructed one layer
    at a time with trucks depositing their loads as close to the previous load as possible. The use
    of tractors or loaders to push material deposited at one location to another location in the
    stockpile shall not be allowed during the construction of the stockpile, and their use shall be
    limited to levelling the deposited material only.

    5 Stockpiles of aggregate located at permanent asphalt plant sites shall be separated by bin
    walls and shall be constructed on asphalt or concrete floors. Stockpile locations and
    procedures at temporary asphalt plant sites shall be as approved by the Engineer.

    6 Intermediate storage of hydrated lime and commercial mineral filler for equipment feeding the
    asphalt plant shall be silos of adequate size to ensure a minimum of one day's continuous
    operation.
    QCS 2014 Section 06: Roadworks Page 14
    Part 05: Asphalt Works

    5.2.10 Inspection and Control

    1 For verification of weights and measures, character of materials and determination of


    temperatures used in the preparation of the asphalt mixes, the Engineer shall at all times
    have access to all portions of the mixing plant, aggregate plant, storage yards, crushers and
    other facilities used for producing and processing the materials of construction.

    2 The Engineer shall have authority to instruct sampling and testing of any material supplied to
    the site from any source whatsoever in order to establish their compliance and to accept or
    reject as he deems necessary. Samples shall also be taken from completed work to
    determine compliance. The frequency of all sampling and testing shall be as designated.

    3 The Contractor shall arrange for obtaining specimens of materials, asphalt mixes and
    samples cut from the paving courses after compaction, including the provision of necessary
    equipment and plant for obtaining these specimens and samples. This work shall be

    l .
    performed in the presence of the Engineer. The Engineer shall take possession of the

    .l.
    samples upon their removal from the roadway unless the Contractor is authorised otherwise

    rw
    4 In particular, the Contractor shall provide a portable coring machine and bits for taking 150
    mm diameter full depth cores of all bituminous paving courses. The coring machine shall be
    available to the Engineer upon request.
    ta
    qa
    5 In addition to the foregoing, one set of three laboratory compacted specimens and one
    uncompacted coated sample for each mix type and mixer plant for each days production,
    as

    shall be delivered to LSA no later than 12 hours after compaction of the specimens together
    with the mix type and project details.
    se

    6 Upon the first erection of the batching plant and at least once every three months thereafter,
    er

    the plant shall be calibrated by a calibration service organisation approved by the LSA.
    ov

    5.3 MARSHALL MIX DESIGN

    5.3.1 General
    it o

    1 The types of bituminous paving mixes shall be as designated on the project drawings or in
    et

    the contract documents.


    m

    2 The LSA shall act as the engineer for the approval of asphalt mix designs and materials
    submitted by the Contractor.

    3 The contractor shall prepare the mix design with all necessary supporting documentation
    which shall include the results of the Contractors own laboratory procedures.

    4 The Contractor shall carry out a trial batching and trial laying of the particular mix design.

    5 The testing and sampling of the mix design by the LSA will take place for both the laboratory
    verification and the trial batching and laying.

    6 Based on the results of the trial batching and laying the contractor may be required to make
    amendments to the mix design. Providing the mix design conforms to the specification the
    mix shall be approved by the LSA.

    7 The LSA shall issue a certification for the job standard mix to the Contractor.
    QCS 2014 Section 06: Roadworks Page 15
    Part 05: Asphalt Works

    8 The approved Job Mix Formula may be amended as a result of experience in the execution
    and performance of the permanent asphalt works. Such an amendment may be submitted by
    the Contractor for the Engineer's approval in which case the Contractor shall submit full
    details of the proposed amendment together with such data as is necessary to support his
    submittal. Amendment may also be directed by the Engineer.

    9 Approval by the Engineer of the Job Mix Formula or amendments thereto shall in no way
    relieve the Contractor of his obligations under the Contract, and the Contractor shall be
    responsible for the soundness of the asphalt paving mixes and the satisfactory execution and
    performance of the asphalt paving courses.

    5.3.2 Marshall Mix Design Criteria

    1 The Asphalt Institute MS-2 Mix Design Methods for Asphalt Concrete and Other Hot-Mix
    Types shall be used in designing the bituminous mixtures using Marshall design method.

    l .
    .l.
    2 The recommended compacted layer thicknesses are shown in Table 5.6.

    rw
    Table 5.6
    Recommended Compacted Layer Thicknesses
    Base Course Base Course ta Wearing
    qa
    (Class A) (Class B) Course(WC)

    80 to 100 mm 60 to 80 mm 45 to 55 mm
    as

    3 When tested according to ASTM C136, the combined mineral aggregate shall conform to
    se

    Table 5.7 for asphalt concrete mixes.


    Table 5.7
    er

    Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes


    ov

    Percentage Passing (By Weight)


    ASTM Sieve Size
    Base Course Base Course
    o

    Wearing Course
    (Class A) (Class B)
    it

    37.5 mm 100 - -
    et

    25.0 mm 80 - 100 100 100


    19.0 mm 62 - 92 80 - 100 86-100
    m

    12.5 mm - 63 - 85 69 - 87
    9.5 mm 45 - 75 57 - 77 58 - 78
    4.75 mm 30 - 55 40 - 60 40 - 60
    2.36 mm 20 - 40 25 - 45 25 - 45
    0.850 mm 15 - 30 15 - 30 15 - 30
    0.425 mm 10 - 22- 10 - 22 10 - 22
    0.180 mm 6 - 15 6 - 15 6 - 15
    0.075 mm 2-8 2-8 2-8

    4 The "Laboratory Designed Mixture" for all types of bituminous coated courses shall comply
    with the requirements given in Table 5.8. Note that any deviation from these requirements
    shall be approved by LSA.
    QCS 2014 Section 06: Roadworks Page 16
    Part 05: Asphalt Works

    Table 5.8
    Design Criteria for Marshall Design Mixes
    Base Course Base Course
    Parameter Wearing Course
    (Class A) (Class B)
    Aggregate Properties Tables 5.1 and 5.2
    Aggregate Grading Table 5.7
    Number of Compaction blows at each
    75 75 75
    end of specimen (see paragraph 5)
    Binder Content (% of total mix)
    3.2 4.4 3.4 4.4 3.4 4.4
    inclusive of tolerances
    Stability minimum (kN) 9.5 min. 9.5 min. 11.5 min.
    Flow (mm) 2 to 4 2 to 4 2 to 4
    Marshall Quotient (Stability/Flow)
    4.75 min. 4.75 min. 4.75 min.
    (kN/mm)

    l .
    .l.
    Voids in Mix (Air Voids) (%) 4 to 8 4.5 to 8 5 to 8

    rw
    Voids in Mineral Aggregate VMA (%) Table No.5.9
    Voids Filled with Asphalt VFA (%) 50 to 70 50 to 75 50 to 75

    ta
    Voids in Marshall Specimen at 400
    Blows per face at optimum binder 3.2 min. 3.4 min. 4.0 min.
    qa
    content (%)
    Retained Stability (%) 75 min. 75 min. 75 min.
    (Filler/Binder) Ratio 0.8 to 1.5 0.8 to 1.5 0.75 to 1.35
    as

    Note: Relevant ASTM standards shall be used for testing.


    5 Base Course (Class B) and Wearing Course samples shall be prepared and tested using
    se

    Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while
    Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
    er

    D5581. However, based on the Engineer approval, samples having aggregate sizes larger
    ov

    than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
    substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
    next lower grading sizes.
    it o

    6 Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
    et

    ASTM D6931 shall be obtained for the mix for quality control purposes. The TSR acceptance
    limits shall be determined at mix design stage and approved by the Engineer.
    m

    Table 5.9
    Minimum Percent Voids in Mineral Aggregate (VMA)
    Minimum VMA, Percent
    Nominal Maximum 3
    1, 2
    Particle Size (mm) Design Air Voids, Percent
    3.0 4.0 5.0
    1.18 21.5 22.5 23.5
    2.36 19.0 20.0 21.0
    4.75 16.0 17.0 18.0
    9.5 14.0 15.0 16.0
    12.5 13.0 14.0 15.0
    19.0 12.0 13.0 14.0
    25.0 11.0 12.0 13.0
    37.5 10.0 11.0 12.0
    50 9.5 10.5 11.5
    63 9.0 10.0 11.0
    QCS 2014 Section 06: Roadworks Page 17
    Part 05: Asphalt Works
    1
    Standard Specification for Wire Cloth Sieves for Testing Purposes, ASTM E11 (AASHTO M92).
    2
    The nominal maximum particle size larger than the first sieve to retain more than 10 percent.
    3
    Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between
    those listed.
    7 After the Job Mix Formula has been established and approved, all mixes furnished shall
    conform thereto within the following tolerances:
    Table 5.10
    Job Mix Tolerances For Field Mixtures
    Base Course Base Course Wearing
    (Class A) (Class B) Courses
    Description
    Aggregate retained on 4.75mm sieve
    5% 4% 4%
    or larger

    l .
    Aggregate passing 4.75mm sieve
    4% 3% 3%

    .l.
    and retained on 850m sieve

    rw
    Aggregate passing 850m sieve and
    3% 2% 2%
    retained on 75m sieve

    Aggregate passing 75m sieve 1.5%


    ta 1.0% 1.0%
    qa
    Binder Content 0.3% 0.2% 0.2%
    as

    8 The Job Standard Mix Density shall be obtained by making six standard Marshall specimens
    from samples of the approved Job Standard Mixture determining the bulk specific gravity of
    se

    each and comparing them with the mean value of the six. Any individual result which differs
    from the mean by more than 0.015 shall be rejected, and provided that not more than two
    er

    results are so rejected the mean of the remaining result shall be designated the Job
    Standard Mixture Density. The absolute density shall be considered as the theoretical
    ov

    specific gravity calculated in accordance with ASTM D2041.

    5.3.3 Quality Control Testing


    it o

    1 The Contractor shall submit a testing plan to the Engineer for approval that demonstrates
    et

    how he shall prove compliance with the requirements for compaction, mix composition, level,
    m

    evenness and all other requirements of Section 6. Each lot shall be approved by the
    Engineer before placing any subsequent asphalt concrete course. In cases where the asphalt
    course is laid in more than one layer, each layer shall be tested and approved before placing
    the subsequent asphalt concrete layer.

    2 In addition to the following requirements one set of three laboratory-compacted specimens


    and one uncompacted coated sample for each mix type and mixer plant for each days
    production shall be delivered to the LSA no later than 12 h after compaction of the
    specimens. Details of compaction date, time and temperature of mix shall be provided with
    the specimens together with mix type and project details.

    3 The Contractor shall cut samples from each completed asphalt course during the progress of
    the work and before final acceptance as directed by the Engineer. The Engineer shall
    determine the location of the samples.

    4 When testing for compaction at joints the edge of the core shall not be more than 50 mm or
    less than 25 mm from the joint.
    QCS 2014 Section 06: Roadworks Page 18
    Part 05: Asphalt Works

    5 Compacted samples shall be taken by coring in accordance with ASTM D5361, for testing by
    an approved laboratory. The core diameter shall be 150 mm. where the Contractor fails to
    provide cores as required by the Engineer, the Engineer may arrange for the taking of cores
    on behalf of the Contractor at his cost. Samples shall be taken of the asphalt mix for the full
    depth of the course. A sample shall comprise a pair of adjacent cores and the average
    density of these shall be the density of the sample.

    6 Whenever deficiencies are noted in loose mix samples or core samples, the Engineer may
    direct the taking of additional cores at the Contractor's expense in order to define the area of
    pavement involved.

    7 Hot asphalt mix of the same type shall be placed and compacted in holes left by sampling.
    The mixture shall be compacted to the percentage compaction required for the layer using a
    vibrating hammer.

    l .
    8 Quality control testing of the asphalt mixtures during construction shall follow the frequencies

    .l.
    shown in Table 5.12 for Marshall Mixtures:

    rw
    9 Base Course (Class B) and Wearing Course samples shall be prepared and tested using
    Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while

    ta
    Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
    qa
    D5581. However, based on the Engineer approval, samples having aggregate sizes larger
    than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
    substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
    as

    next lower grading sizes.


    se

    10 Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
    ASTM D6931 shall be tested for quality control purposes. The TSR acceptance limits shall be
    er

    based on the mix design obtained limits approved by the Engineer.


    ov

    11 If it appears from the analysis of samples of loose mix or cores that the asphalt content or
    aggregate gradation are beyond the permissible tolerances specified for the Job Mix Formula
    (established for each respective asphalt course mix) and that, such variation affects the
    o

    characteristics of the asphalt mix conformity to the designated requirements is concerned,


    it

    this shall be considered a major defect in the work. The portion of the asphalt course
    et

    represented by these samples shall be rejected.


    m

    12 The density of the compacted mixes shall be related to the daily Marshall density determined
    by making minimum four Marshall specimens from samples collected from behind the paver.
    The density of each sample shall be determined and compared with the mean value. Any
    3
    individual result, which varies from the mean by more than 0.015gm/cm shall be rejected.
    The daily Marshall density shall not differ from the Job Mix Design Density by more than
    1.0%.

    13 The field density, as determined from each core sample and related to the daily Marshall
    Density, obtained as shown above, shall be as follows:
    Table 5.11

    Layer Relative Density (%)


    Base Course 97 101.8
    Wearing Course 98 101.8
    QCS 2014 Section 06: Roadworks Page 19
    Part 05: Asphalt Works

    14 The finished road surface shall be inspected visually techniques and if directed by the
    Engineer the structural ability of the pavement in terms of layer modulus shall be assessed
    by using the Falling Weight Deflectometer (FWD) and Light weight Deflectometer (LWD).

    15 For safety purposes the pavement surface friction shall be measured by the pendulum
    portable tester or locked wheel tester in accordance with ASTM E303.
    Table 5.12
    Quality Control Testing of the Marshall Mixtures

    Item / Parameter Standard Specification Limits Minimum Frequency

    Aggregate conformance Sections 5.2.1, 5.2.2 and 5.2.3


    Mineral Filler conformance Section 5.2.5 Every 300t
    Prime Coat conformance Section 5.2.7

    l .
    .l.
    Tack Coat conformance Section 5.2.8
    Asphalt Binder conformance Section 5.2.6

    rw
    2
    0.45 0.75 kg/m 2
    Rate of application for Prime Coat ASTM D2995 - 1 per 250 m
    at 60 85 C
    - 1 every 75m per

    ta
    2
    0.15 0.38 kg/m
    Rate of application for Tack Coat ASTM D2995 lane
    at 10 60 C
    qa
    Sampling of bituminous mixtures ASTM D979 - Test based
    10 C of JMF
    as

    temperature in truck
    BS EN 12697
    135 C min. at paver
    1
    Temperature of bituminous mixture Each truck
    Part 13
    se

    120 C min. prior


    rolling
    2
    1.0% of Job
    er

    ASTM D2726
    Daily Bulk density (See paragraph 12) 3 Daily
    ASTM D1188 Standard Density
    ov

    Table 5.7, Job Mix


    ASTM D5444
    Gradation of extracted aggregates gradation and Table
    ASTM C117
    5.10 tolerances
    o

    ASTM D2172 Job Mix value with


    Binder content
    it

    ASTM D6307 Table 5.10 tolerances


    et

    Marshall Stability, Flow and ASTM D6927 - Each source


    4 Table 5.8
    Stability/Flow Ratio ASTM D5581 - Visible change in
    m

    ASTM C127 material


    Voids in mineral aggregate (VMA) Table 5.9 - 1 test per 300t per
    ASTM C128
    ASTM D2726
    2 layer for Base
    Voids filled with asphalt (VFA) 3 Course
    ASTM D1188
    - 1 test per 150t per
    Voids in Mix (Air Voids) (%) layer for Wearing
    ASTM D2041
    Voids in Marshall Specimen at 400 ASTM D2726
    2 Course
    3 Table 5.8
    Blows per face at optimum binder ASTM D1188
    content (%)
    ASTM D2172
    (Filler/Binder) Ratio ASTM D6307
    ASTM C136
    - 1 test per 600t per
    layer for Base
    ASTM D2041
    2 Course
    In-place air voids ASTM D2726 5 8%
    3 - 1 test per 300t per
    ASTM D1188
    layer for Wearing
    Course
    QCS 2014 Section 06: Roadworks Page 20
    Part 05: Asphalt Works

    Item / Parameter Standard Specification Limits Minimum Frequency


    ASTM D6927 1 test per 3000t per
    Retained Stability (%) (Paragraph 16) 4 75 min.
    ASTM D5581 layer
    5 At 50m intervals in
    Field density (nuclear gauge) ASTM D2950 Table 5.11
    alternate wheel tracks
    ASTM D5361 - 1 test per 200t per
    5 2
    Field density (2 cores) ASTM D2726 Table 5.11 layer for Base Course
    3
    ASTM D1188 - 1 test per 100t per
    ASTM D5361 layer for Wearing
    Thickness Section 5.11.1 Course
    ASTM D3549
    Evenness of surface Section 5.11.2 & 5.11.3
    1
    As per polymer manufacturer recommendation and mix design for polymer modified binders
    2
    If water absorption 2%
    3

    .
    If water absorption > 2%

    l
    4
    For samples containing more than 25mm size aggregates

    .l.
    5
    For acceptance of in-situ compaction

    rw
    16 The Retained Stability is the percentage of the average stability of 3 samples conditioned for
    24 hours at 60 1C water bath and the average stability of 3 samples conditioned for 4

    ta
    hours in 60 1C air bath. These two sets of samples shall be prepared at the optimum
    binder content by applying 75 blows and kept at ambient temperature for 17 20 hours and
    qa
    shall have similar average densities.
    as

    17 Each day the produced mixes shall be tested for checking their compliance with the approved
    Job Standard Mix criteria. When unsatisfactory results or changed conditions make it
    se

    necessary, a new job-standard following approval of new mix design shall be established.
    er

    5.4 DENSE BITUMEN MACADAM


    ov

    1 The mix properties for Dense Bitumen Macadam are listed in Table 5.13.
    Table 5.13
    o

    Properties of Mix for Dense Bitumen Macadam


    it
    et

    Specification Limits
    Parameter Base Wearing
    m

    Course Course
    Number of Compaction blows at each end of specimen 75 75
    Binder Content (% of total mix) inclusive of tolerances 3.2 4.0 3.5 4.1
    Stability minimum (kN) 7.5 10.0
    Flow (mm) 2-4 24
    Marshall Quotient (Stability/Flow) (kN/mm), min 3.7 4.9
    Voids in Mix (Air Voids) (%) 7 - 11 69
    Voids in Mineral Aggregate VMA (%) 14 - 20 14 - 20
    Voids Filled with Asphalt VFA (%) 47 - 60 48 - 60
    Retained stability 75 min. 75 min.

    2 When tested according to ASTM C136, the combined mineral aggregate shall conform to
    Tables 5.14, 5.15 and 5.16.
    QCS 2014 Section 06: Roadworks Page 21
    Part 05: Asphalt Works

    Table 5.14
    Aggregate Gradation for Dense Bitumen Macadam Road Base (Unbound)
    B.S Sieve Aggregate, Crushed Rock or Gravel
    (mm) Percentage by mass passing
    50.0 mm 100
    37.5 mm 95 - 100
    28.0 mm 70 - 94
    14.0 mm 56 - 76
    6.3 mm 44 - 60
    3.35 mm 32 - 46
    0.300 mm 7 - 21
    0.075 mm 2- 8

    Table 5.15

    l .
    Aggregate Gradation for Dense Bitumen Macadam Asphalt Base Course

    .l.
    rw
    Aggregate, Crushed Rock or Gravel
    B.S Sieve
    (mm) Percentage by Mass Passing for Finished Thickness of Base Course
    80 - 100 mm 70 - 90 mm 50 - 70 mm
    50.0 100 -
    ta -
    qa
    37.5 95 - 100 100 -
    28.0 70 - 94 95 - 100 100
    20.0 - 71 - 95 95 - 100
    as

    14.0 56 - 76 58 - 82 65 - 85
    10.0 - - 52 - 72
    se

    6.3 44 - 60 44 - 60 39 - 55
    3.35 32 - 46 32 - 46 32 - 46
    er

    0.300 7 - 21 7 - 21 7 - 21
    ov

    0.075 2 - 8 2 - 8 2 - 8

    Table 5.16
    o

    Aggregate Gradation for Dense Bitumen Macadam Asphalt Wearing Course


    it
    et

    Aggregate, Crushed Rock or Gravel


    B.S Sieve
    m

    (mm) Percentage by Mass Passing for Finished Thickness of Wearing Course


    50 - 60 mm 40 - 50 mm 30 - 40 mm
    28.0 100 - -
    20.0 95 - 100 100 -
    14.0 70 - 90 95 - 100 100
    10.0 55 - 75 70 - 90 95 - 100
    6.3 40 - 60 45 - 65 55 - 75
    3.35 25 - 40 30 - 45 30 - 45
    1.18 15 - 30 15 - 30 15 - 30
    0.075 2 - 6 2 - 6 2 - 6
    QCS 2014 Section 06: Roadworks Page 22
    Part 05: Asphalt Works

    5.5 SUPERPAVE MIX DESIGN

    1 Based on the Engineer approval, the Superpave Mix Design Method can be used to design
    the asphalt mixtures for Wearing Course and Base Course layers. The design of the
    Superpave asphalt mixtures shall follow the method outlined in AASHTO R35 and SP-2
    Asphalt Institute Superpave Mix Design Method in liaison with LSA.

    2 The contractor shall prepare the mix design with all necessary supporting documentation
    which shall include materials production and handling specifications, plant quality procedures,
    construction quality control and quality assurance procedures, quality control tests, mix
    acceptance criteria and performance evaluation testing program. All documentations shall be
    submitted to LSA for review and approval.

    3 Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This

    .
    binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM

    l
    .l.
    D6373 specifications and the criteria listed in Table 5.5.

    rw
    4 Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
    heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
    AASHTO M332 and will be required to indicate elastic response in percent recovery when
    tested in accordance with AASHTO T350.
    ta
    qa
    5 Based on the Engineer approval, the guidelines shown in the Appendix can be used for the
    mix design. Note that software (ePAVE3) shall be validated prior use.
    as

    6 The recent editions of the references shown in the Appendix are recommended to be used
    se

    for preparation of mix design and quality control schemes.


    er

    7 Table 5.17 can be used as a guide for sampling and testing frequency for quality control of
    Superpave mixtures.
    ov

    8 Performance tests shown in Table 5.18 can be used to evaluate performance of Superpave
    asphalt concrete mixtures.
    it o

    9 Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
    et

    Engineer for approval, detailed information for each mix which he proposes to furnish. The
    m

    information shall include, but not be limited to the following:

    (a) Copy of mix certificate approval obtained from LSA and the mix design report.
    (b) The source(s) of the aggregate for each mix as well as the pertinent test data and a
    written certification that the aggregates conform to all of the quality requirements.
    (c) Type of Asphalt modifier intended to be used in the project along with the Certificate of
    Conformity of the modified asphalt binder to the required grade according to the
    Superpave Performance Based Grading System.
    (d) Pertinent test data on the type and properties of the aggregates, asphalt binder,
    modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be
    furnished.
    (e) The type and location of plant to be used for mixing each mix.
    (f) Any other support data and information special to the project (e.g. technical data
    sheets of a polymer in case it was used).
    QCS 2014 Section 06: Roadworks Page 23
    Part 05: Asphalt Works

    Table 5.17
    Sampling and Testing Frequency of Superpave Field Mixtures
    Item / Parameter Standard Specification Minimum Frequency
    Aggregate Conformance Sections 5.2.1, 5.2.2, 5.2.3 and Table 6 - Appendix
    Mineral Filler conformance Section 5.2.5 Every 300t
    Prime Coat conformance Section 5.2.7
    Tack Coat conformance Section 5.2.8
    Asphalt Binder conformance Section 5.2.6
    2
    0.45 0.75 kg/m 2
    Rate of application for Prime Coat ASTM D2995 - 1 per 250 m
    at 60 85 C
    2 - 1 every 75m per
    0.15 0.38 kg/m
    Rate of application for Tack Coat ASTM D2995 lane
    at 10 60 C
    Sampling of bituminous mixtures ASTM D979 - Test based
    10 C of JMF
    temperature in truck
    Min. JMF compaction

    l .
    temperature +20 C at

    .l.
    BS EN 12697
    Temperature of bituminous mixture Each truck
    Part 13 paver

    rw
    Min. JMF compaction
    temperature prior rolling
    (sec. 1.5.4 Appendix)
    Binder content (%)
    ASTM D2172
    ASTM D6307 ta JMF value 0.40
    qa
    Table 9
    Gradation of extracted aggregates ASTM D5444
    Appendix
    Effective Specific Gravity of ASTM D6857
    as

    Gsb < Gse < Gsa - Each source;


    Aggregates (Gse) ASTM D2041
    - Visible change in
    Voids in mineral aggregate (VMA) 1.5
    se

    AASHTO T312 material


    Voids in Mix (Va) ASTM D6857 or - 1 test per 500t per
    ASTM D2041 1.3 layer for Base
    (Min 2 Gyratory specimens at Ndes)
    er

    Density (% of Gmm) at Nmax (Eq. 2) Table 5 Course


    (Min 1 Gyratory specimens at Nmax) ASTM D2726 Appendix - 1 test per 250t per
    ov

    ASTM D6857 / layer for Wearing


    ASTM D2041 Course
    Table 5
    o

    Dust to binder ratio (P0.075 / Pbe) ASTM D2172 /


    Appendix
    ASTM D6307
    it

    ASTM D5444
    et

    Indirect tensile strength (IDT) ASTM D6931 IDT of JMF min.


    m

    ASTM D6931
    Sec. 1.5.8
    Moisture Sensitivity (Retained IDT) Sec. 1.5.8 Weekly
    Appendix
    Appendix
    Dynamic Modulus at 10 Hz, 45 C,
    AASHTO PP60 Min. 1920 MPa
    0kPa confinement
    AASHTO TP79
    Flow Number (Fn) at 54.4 C, 600kPa Procedures A, B Every 10,000t
    deviatory stress, and 0kPa AASHTO PP61 Min. 740
    confinement
    ASTM D5361 - 1 test per 200t per
    In-place air voids 6 8%
    ASTM D2726 layer for Base
    Course;
    ASTM D5361 - 1 test per 100t per
    Thickness Section 5.11.1
    ASTM D3549 layer for Wearing
    Course
    At 50m intervals in
    Field density (nuclear gauge) (%Gmm) ASTM D2950 92 94% alternate wheel
    tracks
    Evenness of surface Section 5.11.2 & 5.11.3
    QCS 2014 Section 06: Roadworks Page 24
    Part 05: Asphalt Works

    5.6 PERFORMANCE EVALUATION OF ASPHALT CONCRETE

    1 Based on the Engineer request, the asphalt mixture performance properties can be
    determined.

    2 The performance properties of asphalt mixtures shall be measured for every asphalt
    concrete layer at least on the following frequencies:

    (a) Prior asphalt laying on a laboratory prepared sample at the asphalt binder content
    specified in the JMF.
    (b) Asphalt mix sampled from behind the paver every 10000t of mix.

    3 The purpose of the performance testing is to allow for pavement performance evaluation and
    verification of pavement structural design through the AASHTO Mechanistic-Empirical
    Pavement Design Guide. Performance models, references, test conditions are shown in table

    l .
    .l.
    5.18 below:

    rw
    Table 5.18
    Performance Models Criteria

    Performance Test
    Test Conditions ta Applications / Use
    qa
    Model Reference
    100X150mm cylindrical
    The E* is used in mechanistic
    AASHTO PP60, sample under uniaxial
    as

    Dynamic Modulus analysis to evaluate the structural


    TP79 Procedure stress, zero confining
    Master Curve responses of the asphalt
    A, & PP61 pressure and sinusoidal
    concrete layers
    se

    deviator stress
    er

    AASHTO PP60 100X150mm cylindrical To evaluate the rutting


    Rutting Model & TP79 sample under triaxial characteristics of the asphalt
    ov

    Procedure B stress mixture in the form of a rutting


    model or Flow Number (FN)
    o

    64x50x380mm beam The initial flexural stiffness is


    it

    specimen is subjected to measured at the 50th load cycle.


    et

    a 4-point bending with Fatigue life or failure shall be


    Fatigue Model AASHTO T321 free rotation and defined as the number of cycles
    m

    horizontal translation at corresponding to 50% reduction


    all load and reaction in the initial stiffness.
    points
    Conduct asphalt binder Viscosity-temperature relationship
    A-VTS test in the (A-VTS) of the asphalt binder is
    Rheometer (DSR) to determined in order to assess the
    Aging Model ASTM D7175 measure G* and in impact of binder aging on the E*
    accordance with ASTM property of the asphalt mix at
    D7175 at multiple various stages of the pavement
    temperatures life

    4 Modelling methods adopted by Asphalt Institute and Shell or equivalent shall be used. The
    contractor shall submit a proposal includes performance modelling testing and interpretation
    procedures to the Engineer for approval.
    QCS 2014 Section 06: Roadworks Page 25
    Part 05: Asphalt Works

    5.7 DELIVERY, SPREADING AND FINISHING

    5.7.1 Delivery of Mixes

    1 Sufficient plant capacity, haul vehicles and storage shall be provided so that adequate
    supplies of mixture are delivered to site to ensure that continuous paving can be achieved.

    2 The dispatching of the hauling vehicles to the job site shall be so scheduled that all material
    delivered may be placed in daylight, unless the Engineer has approved the use of artificial
    light. Delivery of material shall be at a uniform rate and in an amount well within the capacity
    of the paving and compacting equipment.

    3 All precautions shall be taken to protect the mix from the weather during transit and while
    waiting to discharge.

    l .
    4 Hauling vehicles shall not be permitted to carry out tight turns on the laying surface.

    .l.
    rw
    5 The mixture at delivery to the paver shall be within 10 C of the Job Mix Formula temperature
    and above an absolute minimum temperature of 135 C. Material which has fallen below the

    ta
    minimum temperature of 135 C before discharge shall be rejected and immediately removed
    qa
    from site. Delivery temperature shall not exceed the maximum temperature specified for
    mixing at the plant
    as

    6 Should a significant proportion of the mixture delivered to the paver fail to meet this
    requirement, or should cold lumps be found in the mixture, the Engineer shall order that
    se

    paving operations be suspended until measures are taken, to the approval of the Engineer, to
    ensure compliance.
    er

    5.7.2 Spreading and Finishing


    ov

    1 The Contractor shall prepare a paving plan and obtain approval of the Engineer to ensure
    adequate equipment and paving sequences.
    it o

    2 Based on the approved paving plan and prior to the commencement of delivery of the mix the
    et

    Contractor shall erect and maintain an approved reference guide wire for controlling the
    m

    levels of the laid mix. The reference guide wire shall be supported at intervals of not more
    than 5m.

    3 The mix shall be laid upon an approved surface and only when weather conditions are
    suitable and as designated. Upon arrival at the point of use, the asphalt mix shall be spread
    and struck off to the grade, elevation and cross-section shape intended, either over the entire
    width or over such partial width as may be required. If the material does not conform to the
    requirements, it shall not be used and shall be discarded.

    4 The laid material shall be compacted as soon as rolling can be effected without causing
    undue displacement and while the temperature does not fall below 120 C for unmodified
    asphalt mixes. Materials still uncompacted and below this temperature shall be rejected.

    5 The compaction temperature for the laid polymer-modified asphalt binder mixes shall be
    selected based on one of the following:
    (a) As specified in the JMF.
    QCS 2014 Section 06: Roadworks Page 26
    Part 05: Asphalt Works

    (b) As established from the trial section.

    6 The Contractor shall supply accurate calibrated thermometers suitable for measuring the
    inner and surface temperature of the material. The material temperature shall be checked
    immediately before rolling and at least every 30 minutes thereafter during forward progress.
    A record of these temperatures shall be passed to the Engineer at the end of each days
    work.

    7 While paving is in progress, the output of the batching plant shall be exclusively reserved for
    the operations and no mixture shall be supplied to other sites or projects.

    8 If during laying, the paver is repeatedly delayed because of lack of mixture or if the paver
    stands at one location for more than thirty minutes (for any reason), a transverse joint shall
    be constructed. Paving shall not recommence until the Engineer is satisfied that paving will
    proceed uninterrupted and until at least four loaded vehicles have arrived at the paving site.

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    9 The asphalt course shall be constructed to proposed levels and shall be homogeneous,

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    providing after compaction an even surface free from undulations, rises or depressions and
    within the tolerances stipulated.

    10
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    In no case shall construction of a new asphalt concrete course begin until the previously laid
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    course has been tested and approved.

    11 When the same asphalt course is to be laid in more than one layer the second layer shall be
    as

    placed as soon as practicable after the first layer has been finished, rolled and cooled, and
    the Engineer may at his discretion request cleaning of the first layer and the application of a
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    tack coat thereon if he so deems necessary.


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    12 Transverse joints in succeeding layers shall be offset at least 2 m. Longitudinal joints shall
    be offset at least 300 mm.
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    13 The use of motor grader or hand spreading of the asphalt mix shall not be permitted except
    in places where it is impractical to use pavers and shall be only with the specific permission
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    of the Engineer. The asphalt mix shall comply with all conditions regarding trueness of level,
    it

    thickness, and homogeneity of the mix.


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    14 Automatic electronic screed controls shall be required on all pavers and shall be used with a
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    9 m long articulated averaging beam or grade wire control as approved by the Engineer.

    5.7.3 Compaction of Mixes

    1 At least three rollers shall be required at all times, one self-propelled pneumatic-tire and two
    self-propelled steel-wheeled. As many additional rollers shall be used by the Contractor as
    necessary to provide specified asphalt course density and surface characteristics in an
    orderly, efficient and continuous manner.

    2 Before beginning construction of the permanent works, unless otherwise agreed with the
    Engineer, the Contractor shall carry out compaction trials for each type and thickness of
    asphalt course to establish an approved compaction procedure which shall then be used as a
    minimum requirement for the compaction of the permanent works unless otherwise directed
    or agreed by the Engineer.
    QCS 2014 Section 06: Roadworks Page 27
    Part 05: Asphalt Works

    3 The compaction trials shall involve all procedures specified for the permanent works
    including testing as specified for the asphalt course under consideration and any equipment,
    processes or procedures proposed by the Contractor which are not designated. Construction
    of the permanent works shall not commence until a compaction procedure has been
    approved in writing by the Engineer. Such approval shall in no way relieve the Contractor of
    his responsibilities and obligations stipulated in the Contract.

    4 Immediately after the asphalt mix has been spread and struck off, the surface shall be
    checked and any irregularities adjusted and then compacted thoroughly and uniformly by
    rolling.

    5 To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly
    moistened but excess water shall not be permitted.

    6 After the longitudinal joints and edges have been compacted, rolling shall start longitudinally

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    at the sides of the road and shall gradually progress towards the centre. On super elevated

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    sections, rolling shall begin on the low side and progress to the high side, overlapping on

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    successive trips by at least one-half the width of tandem rollers and uniformly lapping each
    proceeding track. The rollers shall move at a slow but uniform speed with the drive wheels
    nearest the paver. The speed shall not exceed 4-5 km/h for steel-wheeled rollers or 8 km/h

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    for Pneumatic-tire rollers. The operating speed shall be approved by the Engineer.
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    7 The line of rolling shall not be changed suddenly or the direction of rolling reversed suddenly.
    If rolling causes displacement of the material, the affected areas shall be loosened at once
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    with hand tools and restored to the original grade of the loose material before being rerolled.
    Heavy equipment or rollers shall not be permitted to stand on the finished surface before it
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    has been compacted and has thoroughly cooled.


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    8 When paving in a single width, the first lane placed shall be rolled in the following order:
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    (a) Transverse joints.


    (b) Longitudinal joints.
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    (c) Outside edge.


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    (d) Initial or breakdown rolling, beginning on the low side and progressing towards the high
    side.
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    (e) Intermediate rolling.


    (f) Final rolling.
    1 When paving in echelon, 50 mm to 100 mm of the edge which the second paver is following
    shall be left unrolled. When paving in echelon the edges between the first and the second
    paver shall not be exposed more than 15 minutes nor 50m by distance without being rolled.
    Particular attention shall be given to the construction of the transverse and longitudinal joints
    in all courses.

    5.7.4 Transverse Joints

    1 Transverse joints shall be carefully constructed and thoroughly compacted to provide a


    smooth riding surface. Joints shall be checked with a straightedge to assure smoothness and
    true alignment. Joints shall be formed with a bulkhead, such as a board, to provide a straight
    line and vertical face.
    QCS 2014 Section 06: Roadworks Page 28
    Part 05: Asphalt Works

    2 If the joint has been distorted by traffic or by other means, it shall be trimmed to line and the
    face shall be painted with thin coating of emulsified asphalt before the fresh material is
    placed against it. To obtain thorough compaction of these joints the material placed against
    the joint shall be tightly pushed against the vertical face with a steel-wheeled roller.

    3 The roller shall be placed on the previously compacted material transversely so that not more
    than 150 mm of the rear rolling wheel rides on the edge of the joint. The roller shall be
    operated to pinch and press the mix into place at the transverse joint. The roller shall
    continue to roll along this line, shifting its position gradually across the joint, in 150 to 200 mm
    increments, until the joint has been rolled with the entire width of the roller wheel. Rolling
    shall be continued until a thoroughly compacted, neat joint is obtained.

    5.7.5 Longitudinal Joints

    1 Longitudinal joints shall be rolled directly behind the paving operations. The first lane placed

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    shall be true to line and grade and have a vertical face. The material being placed in the

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    abutting lane shall then be tightly pushed against the face of the previously placed lane.

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    Rolling shall be done with a steel-wheeled roller.

    2 The roller shall be shifted over onto the previously placed lane so that not more than 150 mm

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    of the roller wheel rides on the edges of the newly laid lane. The rollers shall then be
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    operated to pinch and press the fine material gradually across the joint. Rolling shall be
    continued until a thoroughly compacted, neat joint is obtained.
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    3 When the abutting lane is not placed in the same day, or the joint is distorted during the day's
    work by traffic or by other means, the edge of the lane shall be carefully trimmed to line,
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    cleaned and painted with a thin coating of emulsified asphalt before the adjacent lane is
    placed.
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    4 The longitudinal joints in the surface course shall be along the same line as the traffic lane
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    markers.

    5.7.6 Paving Edges


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    1 The edges of the asphalt course shall be rolled concurrently with or immediately after rolling
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    the longitudinal joint.


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    2 Care shall be exercised in consolidating the course along the entire length of the edges.
    Before it is compacted, the material along the unsupported edges shall be slightly elevated
    with hand tools. This will permit the full weight of the roller wheel to bear on the material to
    the extreme edges of the mat.

    5.7.7 Breakdown Rolling

    1 Breakdown rolling shall immediately follow the rolling of the longitudinal joints and edges.
    Rollers shall be operated as close to the paver as possible to obtain adequate density without
    causing undue displacement. In no case shall the mix temperature be allowed to drop below
    120 C before breakdown rolling.

    2 If the breakdown roller is steel wheeled, it shall be operated with the drive wheel nearest the
    finishing machine. Pneumatic-tire rollers may be used as breakdown rollers.
    QCS 2014 Section 06: Roadworks Page 29
    Part 05: Asphalt Works

    5.7.8 Intermediate Rolling

    1 Pneumatic-tire rollers or Steel wheeled rollers shall be used for the intermediate rolling.

    2 The intermediate rolling shall follow the breakdown rolling as closely as possible and while
    the paving mix is still hot. Rollers shall be used continuously after the initial rolling until all of
    the mix placed has been thoroughly compacted. Turning of rollers on the hot paving mix
    which causes undue displacement shall not be permitted.

    5.7.9 Finish Rolling

    1 The finish rolling shall be performed with three-axle tandem rollers unless otherwise
    permitted by the Engineer. Finish rolling shall be accomplished while the material is still warm
    enough for the removal of roller marks.

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    2 All rolling operations shall be conducted in close sequence.

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    3 In places inaccessible for the operation of standard rollers as specified, compaction shall be
    performed by manual or mechanical tampers of such design as to give the desired density.

    4
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    After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
    and any irregularity of the surface exceeding the specified limits and any areas defective in
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    texture, density or composition shall be corrected as directed by the Engineer, including
    removal and replacement as directed by the Engineer.
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    5.7.10 Protection of Laid Courses


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    1 Sections of the newly finished work shall be protected from traffic of any kind until the mix
    has been properly compacted and cooled. In no case shall traffic be permitted less than 24 h
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    after completion of the asphalt course unless a shorter period is authorised by the Engineer.
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    5.8 COLD PLANING


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    1 The cold planing plant shall be to the approval of the Engineer.


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    et

    2 Cold planing plant shall have sufficient power, traction and stability to maintain the required
    depth of cut and slope. The control of the depth of cut and the slope shall be by an automatic
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    system based on reference wires.

    3 Cold planing shall be carried out to straight crossfalls to the designated thickness. Planing
    shall be to a tolerance of 5 mm of the designated amount. The average thickness of
    planing achieved shall be at least the thickness designated.

    4 In areas where there is severe deformation of the existing pavement, it may be necessary to
    vary the depth of planing.

    5 Existing kerbs, gullies, manholes and other features shall not be disturbed by the planing
    process. This may require the use of smaller plant or removal by hand tools.

    6 Any joints at the edge of planed areas shall be cut vertically and straight using asphalt saws.

    7 Cold planing shall be carried out in a longitudinal direction.


    QCS 2014 Section 06: Roadworks Page 30
    Part 05: Asphalt Works

    8 After planing the prepared surface shall be thoroughly brushed and suction swept by
    mechanical means to the satisfaction of the Engineer. The surface shall be free from
    gouges, ridges, continuous grooves and shall have a reasonably uniform finish.

    9 Cold planing shall be performed so that at the end of a days work the termination line does
    not present a hazard to traffic that may use the road.

    10 Any cracks noted in the pavement shall be blown clean with compressed air. The Engineer
    will inspect the planed surface and may instruct that further work is carried out for treating
    cracks in the pavement.

    5.9 PRIME COAT

    5.9.1 General

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    1 The work shall consist of furnishing and applying liquid asphalt and blotter material, if

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    required, to a previously prepared and approved subgrade or granular base/sub-base course

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    as designated and to the full designated width.

    2 Prime coat shall not be applied when the ambient temperature is less than 13 C nor during
    rain, fog, dust storms or other unsuitable weather.
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    5.9.2 Equipment Required
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    1 The equipment used by the Contractor shall include a liquid asphalt distributor as described
    in clause 5.17.3.
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    2 If the surface is covered in wind-blown dust or fine aggregate then a power broom shall be
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    provided. The power broom shall be self-propelled and equipped with a cylindrical, rotating
    nylon bristle brush of not less than 760 mm in diameter and not less than 1800 mm in length.
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    The brush shall be capable of being angled to the right and left with adjustable ground
    pressure. Where necessary for the proper preparation of the surface, motor graders, rollers
    and water trucks shall also be provided.
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    5.9.3 Surface Preparation


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    1 Immediately before applying the prime coat, all loose dirt, earth and other objectionable
    material shall be removed from the surface with a power broom of approved design and/or a
    power blower as required, and any ruts, soft spots or unacceptable irregularities in the
    surface shall be repaired in accordance with the instructions of the Engineer. If the Engineer
    so requires, the surface shall be lightly bladed and rolled immediately before the application
    of the prime coat, in which case brooming or blowing may not be required.

    2 Priming will not be permitted when there is free water present on the surface.

    5.9.4 Application

    1 After preparing the road surface as above, the prime coat shall be applied by means of the
    distributor at the temperature and rate shown in Table 5.12. Hand-spraying of restricted,
    inaccessible areas is permitted, subject to the approval of the Engineer.

    2 The surface of structures, kerbstones and other appurtenances adjacent to areas being
    treated shall be protected in such a manner as to prevent their being spattered or marred.
    QCS 2014 Section 06: Roadworks Page 31
    Part 05: Asphalt Works

    3 The prime coat shall usually be applied to 1/3 or 1/2 of the road width at a time. When
    applied in two or more lanes, there shall be a slight overlap of asphalt material along
    adjoining edges of the lanes. It should be noted that no overlapping is allowed at the
    transverse joints and that thick paper shall be used at the joint to protect the previous
    application and the joining application shall begin on the paper. The paper used shall be
    removed and satisfactorily disposed of by the Contractor after use. Care shall be taken that
    the application of prime coat material at the junctions of spread is not in excess of the
    specified amount. Excess bituminous material shall be removed from the surface.

    5.9.5 Maintenance and Traffic

    1 Traffic shall not be permitted on the primed surface until the asphalt material has penetrated
    and dried and, in the judgement of the Engineer, will not be picked up under traffic. If it
    becomes necessary to permit traffic before that time, but in no case sooner than 48 hours
    after the application of the asphalt material, blotter material shall be applied as directed by

    l .
    the Engineer and traffic shall be permitted to use the lanes so treated.

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    2 Blotter material shall be spread from trucks operated backward so that the wheels will not
    travel in uncovered wet asphalt material. When applying blotter material to an asphalt treated
    lane that adjoins a lane that has not been treated, a strip at least 200 mm wide along the

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    adjoining edge shall be left devoid of blotter material in order to permit an overlap of asphalt
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    material.

    3 The Contractor shall maintain the primed surface in good clean condition and before the
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    application of the next course, any surface irregularities shall be corrected and all excessive
    blotter material, dirt or other objectionable materials shall be removed.
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    5.10 TACK COAT


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    5.10.1 General
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    1 This work shall consist of furnishing and applying diluted emulsified asphalt to a previously
    prepared Base or Wearing courses, to provide bond for a superimposed course to the full
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    designated width.
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    et

    2 Tack coat shall not be applied when the ambient temperature is less than 13C nor during
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    rain, fog, dust storms or other unsuitable weather.

    5.10.2 Equipment Required

    1 The equipment used by the Contractor shall include liquid asphalt distributor as well as a
    power broom and a power blower. Power broom shall be self-propelled and equipped with a
    cylindrical, rotating nylon bristle Brush of not less than 760 mm in diameter and not less than
    1800 mm in length. The brush shall be capable of being angled to the right and left with
    adjustable ground pressure. In addition, the Contractor shall supply and use efficient and
    approved equipment for diluting the emulsified asphalt with water.
    QCS 2014 Section 06: Roadworks Page 32
    Part 05: Asphalt Works

    5.10.3 Surface Preparation

    1 The full width of the surface to be treated shall be cleaned with a power broom or power
    blower to remove dust, dirt or other objectionable materials. All faulty or unsuitable patches,
    excess cracks or joint filler and all surplus bituminous material shall be corrected in
    accordance with the instructions of the Engineer. The surface shall be dry when treated.

    5.10.4 Application

    1 Immediately after cleaning the surface, the tack coat shall be applied by means of the
    distributor at the temperature and rate directed by the Engineer. Hand spraying of restricted,
    inaccessible areas is permitted, subject to the approval of the Engineer.

    2 The diluted emulsion shall be applied at a rate shown in Table 5.12. The Contractor shall
    ensure that excessive application of tack coat is avoided.

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    3 The surface of structures, kerbstones and other fixed objects adjacent to areas being treated

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    shall be protected in such a manner as to prevent their being spattered or marred.

    5.10.5 Maintenance and Traffic

    1 ta
    After application, the surface shall be allowed to dry until it is in a proper condition of
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    tackiness to receive the superimposed course. Tack coat shall be applied only so far in
    advance of the superimposed course placement as is necessary to obtain this proper
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    condition of tackiness.
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    2 Until the superimposed course is placed, the Contractor shall protect the tack coat from
    damage.
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    3 If the tack coat is unavoidably damaged by rain or dust, it shall be allowed to dry, shall be
    ov

    cleaned again by a power broom or power blower and, if required by the Engineer, a
    subsequent light application of tack applied to the surface. Where, in the opinion of the
    Engineer, a tack coat is not necessary between layers of freshly placed courses, he may give
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    instructions in writing to omit the tack coat. Any cleaning required in these areas shall be
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    carried out before the application of the next course.


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    5.11 THICKNESS AND LEVEL


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    5.11.1 Thickness

    1 Cores shall be taken to determine the thickness of asphalt paving courses. As determined
    from each core, the thickness of a paving course shall not be less than that specified by more
    than 5 mm in the case of a single-layered construction. Furthermore, the thickness of the
    Wearing course shall not be less than that specified by more than 5 mm and the total
    thickness of all asphalt paving courses combined shall not be less than that specified by
    more than 10 mm.

    2 In addition, the variations in the falls to cross sections of the road shall not vary from the
    required value by more than 0.3 %. Any asphalt paving course containing deviations or
    variations exceeding these tolerances shall be corrected or removed and replaced by the
    Contractor, in accordance with the instructions and to the satisfaction of the Engineer.
    QCS 2014 Section 06: Roadworks Page 33
    Part 05: Asphalt Works

    3 Where any individual course is marginally out of tolerance on the low side, the Engineer may
    allow adjustment in the succeeding course to correct the overall thickness of the pavement.

    4 The tolerances herein specified shall not invalidate the tolerances set forth for the evenness
    of surface of the asphalt paving course.

    5 As directed by the engineer the laid thickness shall be checked by cutting test pits and/or
    using Ground Penetrating Radar (GPR) for the determination of the structural capacity of the
    pavement.

    5.11.2 Transverse Evenness

    1 The Engineer shall test the evenness of surface for each course of the various asphalt
    paving courses to determine compliance.

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    2 The Contractor shall put at the disposal of the Engineer a 3m long straight edge and a crown

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    template of sturdy and approved design and enough labour to assist in the checking

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    operations. The maximum allowable differences between the pavement surface and the
    straight edge shall be 3mm. Transverse measurements shall be carried out every 20m of
    road length for each lane.

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    Any layer containing deviations or variations exceeding the tolerances specified here shall be
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    corrected or removed and replaced in accordance with the instructions of the Engineer and to
    his satisfaction.
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    5.11.3 Evenness and Rideability


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    1 Smoothness is a measure of the evenness and rideability of the pavement surface. It shall be
    measured on the driving surface of the completed pavement for all major roads before
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    opening to the traffic.


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    2 Any section containing deviations or variations exceeding the criteria specified here or by the
    Engineer shall be corrected or removed and replaced in accordance with the instructions of
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    the Engineer and to his satisfaction at the Contractors cost.


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    et

    3 The minimum length of the rectification work undertaken shall be 100m.


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    4 All rectified segments shall be re-tested following the completion of rectification work at no
    additional cost to the client.

    (a) Evenness

    5 The evenness of the driving surface of road pavements shall be measured with a 3m rolling
    straight edge along any line or lines parallel to the center line of the pavement on sections of
    300m selected by the Engineer, whether or not it is constructed in shorter lengths. Sections
    shorter than 300m forming part of a longer pavement shall be assessed using the number of
    irregularities for a 300m length prorated to the nearest whole number. Where the total length
    of pavement is less than 300m the measurements shall be taken in 75m lengths.

    6 The number of deviations (from the bottom face of the straight edge) over the length of the
    section greater than or equal to 4mm shall be counted. None of the measured deviations
    shall exceed 6mm. The evenness of the driving surface of the tested section shall be within
    the relevant limits given in Table 5.19.
    QCS 2014 Section 06: Roadworks Page 34
    Part 05: Asphalt Works

    Table 5.19
    Evenness of Driving Surface
    Section Length (m) Allowed number of deviations 4mm
    300 20
    75 9

    (b) Rideability

    7 For major roads the International Roughness Index (IRI) shall be used to monitor the
    roughness and condition of the pavement surface. The acceptable IRI for ride quality shall be
    decided by the Engineer.

    8 The rideability of the driving surface of the completed pavement shall be measured in terms
    of the International Roughness Index (IRI) which shall be tested with a certified and

    .
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    calibrated Inertial Profiler meeting the requirements of ASTM E950Class 1.

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    9 The testing method shall be in accordance with ASTM E950. The IRI shall be calculated
    according to ASTM E1926.

    10
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    Calibration checks on the inertial profiler shall be conducted using test methods in
    accordance with the manufacturers recommendations, at the beginning of the day of
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    operation and at any other time the operator may suspect changes of system performance
    since the last calibration.
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    11 Calibration checks on the inertial profiler and all other quality checks shall be submitted in a
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    method statement to the Engineer for approval.


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    12 The selected measuring speed shall be the posted speed and within the range
    recommended by the manufacturer and shall remain nearly constant during testing, not to
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    exceed +/-5 km/h of the selected speed.

    13 The profiler system shall stabilize at the test speed prior to entering the test sections. This
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    requires bringing the profiler vehicle to the desired test speed at least 100 m prior to the
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    beginning of the test location. Any Features along the test section such as bridges, culverts,
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    milepost or other pertinent information shall be identified. The test shall be conducted in the
    paving direction.
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    14 The start and end point of the test section shall be automatically identified by using a photo
    detector. The coordinates of the test section shall be identified by using a GPS.

    15 Three runs of data collection (both wheel tracks in each lane) shall be conducted. The
    processing of the data for IRI shall include calculating the average IRI value of the three runs
    for the two wheel tracks. The processed data shall be reported on 25m and 400m sub-
    sections calculated using the Moving Average statistical method and applying a 250mm
    filtering.
    QCS 2014 Section 06: Roadworks Page 35
    Part 05: Asphalt Works

    5.12 PAVEMENT EVALUATION TECHNIQUES

    1 Pavement evaluation tests shall be carried out for the completed pavement structure at any
    point of the road as directed by the Engineer to assess the serviceability condition of the
    pavement and verify compliance with specifications.

    2 Pavement evaluation methods can be grouped into two main categories, destructive and
    non-destructive.

    3 The Contractor shall allow and provide all necessary arrangements for the execution of all
    pavement evaluation test required by the Engineer.

    4 As directed by the Engineer the structural ability of the pavement in terms of load-deflection
    response and layer modulus shall be assessed by using the Falling Weight Deflectometer
    (FWD).

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    5 The pavement surface friction shall be measured based on the Engineer request using the

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    portable pendulum tester (ASTM E303), locked wheel tester (ASTM E274) or the sand patch
    method (ASTM E965).

    5.13 PRODUCTION OF ASPHALT CONCRETE COURSES


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    5.13.1 Weather Limitations
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    1 Production and spreading of asphalt Concrete mix shall not be permitted when the ambient
    temperature is less than 8 C, nor during rain, fog, dust-storms or other unsuitable weather.
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    5.13.2 Equipment Required


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    1 The equipment required for construction of the asphalt concrete courses shall include but not
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    be limited to the equipment mentioned in Clauses 5.3 to 5.6 of this Part, together with such
    miscellaneous equipment and tools as required for the satisfactory preparation and
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    performance of the work.


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    2 All equipment shall be checked, calibrated and approved by the Engineer before use. The
    equipment shall be satisfactorily maintained and shall be used in an approved manner.
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    3 Adequate equipment and labour shall be used so that there is continual production and
    distribution of the asphalt course being constructed.

    5.13.3 Survey and Preparation

    1 The area to be paved shall be true to line and grade and shall have a properly prepared
    surface before the start of paving operations.

    2 When an asphalt concrete pavement course is to be placed on top of an existing pavement,


    the existing pavement surface shall be prepared as designated by the Engineer.

    3 Priming or tacking of surfaces to be paved shall be carried out as designated.


    QCS 2014 Section 06: Roadworks Page 36
    Part 05: Asphalt Works

    4 The surface of kerbs, vertical faces of existing pavements and all structures in actual contact
    with asphalt mixes shall be painted with a thin and complete coating of tack coat as
    instructed by the Engineer to provide a closely bonded, watertight joint.

    5 All openings or structures in the road for water, drainage and other specified utilities shall be
    constructed and their positions and levels determined before the start of paving operations.

    5.13.4 Heating of Asphalt Binder

    1 The 60/70 penetration grade bitumen shall be heated to a temperature of between 150 to 165
    degrees centigrade.

    2 Bitumen of other penetration grade shall be heated to yield viscosity's in the range of 150 to
    300 centistokes (175 to 150 seconds Saybolt-Furol) when delivered to the mixer, as
    determined from the Temperature Viscosity Chart of the product used.

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    3 Penetration Graded Asphalt Binders shall not be used if foaming occurs or shall it be heated

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    above 175 C at any time.

    4 Polymer-modified binder shall be heated to a temperature specified by the supplier.

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    5.13.5 Heating of Mineral Aggregate

    1 When using 60/70 penetration grade asphalt binder the materials shall be thoroughly dried
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    and heated so that their temperature is 165 to 180 degrees centigrade.


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    2 When using asphalt binder of other penetration grade the materials shall be thoroughly dried
    and heated so that their temperature is within 8 C of the temperature needed to satisfy the
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    viscosity requirements of the asphalt cement.


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    3 The moisture content of the heated and dried materials shall not exceed 1%.
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    4 The quantity of materials fed through the drier shall in all cases be held to an amount which
    can be thoroughly dried and heated within the limits specified.
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    et

    5 The heated materials shall be screened into sizes such that they may be combined into a
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    gradation meeting the requirements of the Job Mix Formula and the hot aggregate storage
    bins shall be such as to minimise segregation and loss of temperature of aggregate.

    6 Hot bins shall be drawn and cleaned of material at the end of each day's operation.

    5.13.6 Proportioning and Mixing

    1 The heated ingredients together with the mineral filler and bitumen shall be combined in such
    a manner so as to produce a mixture which complies with the requirements of the Job Mix
    Formula. Plant settings, once established, shall not be changed without the approval of the
    Engineer.

    2 Mineral filler, in a cool dry state, shall be proportioned into the mixer either with the aggregate
    or after the introduction of the bitumen to avoid loss of fines that may occur in dry mixing as a
    result of turbulence in the mixer.
    QCS 2014 Section 06: Roadworks Page 37
    Part 05: Asphalt Works

    3 In batch type plants a dry mixing period of not less than four seconds shall precede the
    addition of the bitumen to the mix. Excess wet mixing shall be avoided. Wet mixing shall
    continue as long as it is necessary to obtain a thoroughly blended mix but shall not exceed 75
    seconds nor be less than 30 seconds.

    4 Once approved, mixing times shall not be altered unless so ordered or further approved by
    the Engineer.

    5.14 HAULING EQUIPMENT

    1 Vehicles used for the transport of aggregates or bituminous mix shall have tight, clean and
    smooth insulated metal bodies and shall be free from dust, screenings, petroleum oil and
    volatile or other mineral spirits which may affect the material being hauled. The vehicle metal
    bed shall, if required, be sprayed with a minimum amount of soapy water or lime solution to

    .
    prevent the bituminous mix from adhering to the bed. After spraying, the truck shall be raised

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    and thoroughly drained and no excess solution shall be permitted. Use of diesel or other
    solvents to spray in the truck bed is prohibited.

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    2 Provision shall be made for covering truck loads with canvas or other suitable material of
    such size that the bituminous mix is fully covered.
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    3 Any truck causing excessive segregation of material by its spring suspension or other
    contributing factors, or that shows oil leaks in detrimental amounts, or that causes undue
    delays, shall, upon the instruction of the Engineer, be removed from the work until such faults
    as

    are corrected.
    se

    4 End dump trucks shall be equipped with chains on the tail gates for control when dumping
    the mix into the paving machine. Hauling trucks shall not be routed over wet or muddy
    er

    access ways such that tires accumulate dirt that is deposited on the laying surface.
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    5 The Contractor shall provide an adequate number of trucks of such size, speed and condition
    to ensure orderly and continuous progress of the work all to the approval of the Engineer.
    o

    5.15 OTHER EQUIPMENT


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    et

    5.15.1 Spreading and Finishing Equipment


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    1 The asphalt mixture shall be fed to the paver by end tipping of the truck or by means of a
    windrow elevator. The equipment for spreading and finishing the asphalt mixtures shall be of
    an approved mechanical, self-powered electronic controlled floating screed type, capable of
    spreading and finishing the mixture true to line, grade and required crown.

    2 The pavers shall be self-propelled and equipped with hoppers and distributing screws of the
    reversing type to place the mixture uniformly in front of adjustable electronic controlled
    screeds. The pavers shall be so designed to allow a minimum paving width of 2 m, although
    paving in widths of less than 3 m will require the approval of the Engineer.

    3 Pavers shall be equipped with such provisions and attachments to suit paving widths
    specified for road widening as well to as to suit paving on sloped sections. They shall be
    equipped with fast and efficient steering devices and shall have reverse as well as forward
    travelling speeds. The operational speed of the pavers shall be adjustable from 3 to 6 m/min
    in accordance with the instructions of the Engineer.
    QCS 2014 Section 06: Roadworks Page 38
    Part 05: Asphalt Works

    4 The pavers shall employ mechanical devices as equalising runners, straight edge runners,
    evener arms or other compensating devices to maintain trueness of grade and to confine the
    edges of the pavement to true lines without the use of stationary side forms. The equipment
    shall include blending or joint levelling devices for smoothing and adjusting longitudinal joints
    between lanes. The assembly shall be designed and operated in such a manner that it will
    place the material at the required compacted thickness.

    5 Electronic screeds shall include automatic feed controls to maintain a constant level of
    material along the full length of the screed, automatic grade control and automatic slope
    control. Unless waived by the engineer, on projects with smoothness (IRI) requirements, the
    paver shall carry minimum 9.0m long average beam equipped with an ultrasonic sensors
    capable of sensing a pavement section at several spatially separated spots. The automatic
    slope control shall be equipped with a proportioning manual override to enable smooth
    transition of changing slope rate. Automatic screed controls shall be approved by the
    Engineer before use.

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    6 Screeds shall be provided with devices for heating the screeds to the temperature required

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    for the laying of the mixture without pulling or marring. Pavers shall also be provided with the
    standard attachable screed extensions. All screeds shall be of the vibrating type that permits
    material to be tamped into position.

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    7 The term "screed" includes any cutting, crowning or other physical action that is effective in
    producing a finished surface of the evenness and texture specified, without tearing, shoving,
    or gouging.
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    8 If, during construction, it is found that the spreading and finishing equipment in operation
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    leaves in the pavement surface tracks or indented areas or other objectionable irregularities
    that are not satisfactorily corrected by scheduled operations, the use of such equipment shall
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    be discontinued and other satisfactory spreading and finishing equipment shall be provided
    by the Contractor.
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    5.15.2 Rolling Equipment


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    1 Rolling equipment shall consist of vibratory steel-wheeled rollers, dead weight steel-wheeled
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    rollers and pneumatic-tire rollers as required for proper compaction and finishing of the
    et

    asphalt surface. Unless otherwise permitted, rollers shall be equipped with reversible or dual
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    controls to allow operation both forward and backward with the operator always facing in the
    direction of movement.

    2 Steel-wheeled rollers shall be two-axle tandem rollers or three-axle tandem rollers. These
    rollers shall be self-propelled and equipped with power units of not less than four cylinders
    and under working conditions shall develop contact pressures under the compression wheels
    of 45 to 65 kg/cm of width. Each two-axle roller shall have a minimum weight of 10,000 kg
    each and three-axle roller shall have a minimum weight of 13,000 kg. Vibrating steel-wheeled
    rollers shall have dual drums with a minimum weight of 7000 kg. Vibrating frequency shall be
    between 2000 and 3000 cycles per minute with individual controls for each tandem drum.
    Rollers shall be in good working condition and shall be equipped with a reversing clutch.
    Rollers shall be equipped with adjustable scrapers to keep the wheel surface clean and with
    efficient means of keeping them wet to prevent mixes from sticking. These surfaces shall
    have no flat areas or projections which will mark the surface of the asphalt courses. The
    three-axle rollers shall be equipped with a centre axle which may be operated either fixed or
    floating. The three-axle tandem roller shall be so constructed that when locked in a position
    QCS 2014 Section 06: Roadworks Page 39
    Part 05: Asphalt Works

    for all treads to be in one plane, the roller wheels are held with such rigidity that, if either front
    or centre wheel is unsupported the other two wheels will not vary from the plane by more than
    6 mm. All steel-wheeled rollers shall be in good condition and the Contractor shall furnish to
    the Engineer the manufacturers technical data for each roller and no roller shall be used
    except after approval of the Engineer.

    3 Pneumatic-tire rollers shall be self-propelled. The rollers shall be equipped with pneumatic
    tires of equal size and diameter which are capable of exerting varying average contact
    pressure. Pneumatic-tire rollers shall be in good condition and with enough ballast space to
    provide uniform wheel loading as may be required. The Contractor shall furnish to the
    Engineer charts or tabulations showing the contact areas and contact pressures for the full
    range of tire inflation pressures and for the full range of tire loading for each type and size
    compactor tire furnished and used in pneumatic-tire rollers. The total operating weight and
    tire pressure may be varied by the order of the Engineer to obtain contact pressures which

    .
    will result in the required asphalt course density.

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    5.15.3 Liquid Asphalt Distributor

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    1 The liquid asphalt distributor truck shall be of the pressure type with insulated tanks. The use

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    of gravity distributors will not be permitted. The distributor shall have pneumatic tires of such
    width and number that the load produced on the road surface shall not exceed 100 kg/cm tire
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    width.

    2 Spray bars shall have a minimum length of 2.4 m and shall be of the full circulating type.
    as

    Spray bar extensions shall also be of the full circulating type. The spray bar shall be
    adjustable to maintain a constant height above the surface to be treated.
    se

    3 The spray bar nozzles shall be slotted and shall be of such design so as to provide a uniform
    er

    unbroken spread of asphalt material on the surface. The valves shall be operated by levers
    so that one or all valves may be quickly opened or closed in one operation. The distributor
    ov

    shall be equipped with a hose and nozzle attachment to be used for spotting areas
    inaccessible to the distributor. The distributor and booster tanks shall be so maintained at all
    o

    times as to prevent dripping of liquid asphalt material from any part of the equipment.
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    et

    4 The distributor shall be equipped with devices and charts to provide for accurate and rapid
    determination and control of the amount of liquid asphalt material being applied and with a
    m

    tachometer of the auxiliary wheel type reading speed in m/min. The spreading equipment
    shall be provided with a separate power unit for the pump or a variable displacement pump
    driven by a hydrostatic transmission so that a uniform application of liquid asphalt material, in
    2
    controlled amounts, may be made ranging from 0.15 to 5.0 kg/m . The distributor shall have
    satisfactory heating equipment and thermometers in order to provide the full range of
    application temperatures for the liquid asphalt material being used.

    5 Before commencing the work and as required by the Engineer, the liquid asphalt distributor
    shall be checked and calibrated such that the rate of transverse spread or longitudinal spread
    shall not vary more than 10 % from the required rate of application.
    QCS 2014 Section 06: Roadworks Page 40
    Part 05: Asphalt Works

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    APPENDIX ta
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    QCS 2014 Section 06: Roadworks Page 41
    Part 05: Asphalt Works

    1 APPENDIX - ASPHALT WORKS........................................................................... 42


    1.1 DEFINITIONS ........................................................................................................ 42
    1.2 INTRODUCTION ................................................................................................... 44
    1.3 SUPERPAVE DESIGN PARAMETERS ................................................................. 44
    1.3.2 Traffic 44
    1.3.3 Nominal Maximum Aggregate Size (NMAS) 45
    1.4 SELECTION OF HMA PROPERTIES & REQUIREMENTS ................................... 46
    1.5 OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS....................................... 47
    1.5.2 Step1: Selection of Materials 47
    1.5.3 Step2: Selection of a Design Aggregate Structure (DAS) 48

    .
    1.5.4 Work Instructions of Step 2 Selection of DAS 50

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    1.5.5 Step 3: Selection of the Design Asphalt Content 51
    1.5.6 Work Instruction of Step 3- Selection of DAC 52

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    1.5.7 Nmax and Ndes Verification 52
    1.5.8 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture 53
    1.5.9
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    Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity 54
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    1.6 JOB MIX DESIGN PROPOSAL ............................................................................. 54
    1.6.2 Acceptance of Job Mix Formula 55
    1.6.3 Construction Quality Control: 56
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    1.7 REFERENCES ...................................................................................................... 57


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    QCS 2014 Section 06: Roadworks Page 42
    Part 05: Asphalt Works

    1 APPENDIX - ASPHALT WORKS

    1.1 DEFINITIONS

    1 Superpave: Is an abbreviation of Superior Performing Asphalt Pavement. Superpave


    system consist the following steps:

    (a) Performance-Based Asphalt Binder Grading System


    (b) Performance-Based Specifications of Materials & HMA.
    (c) Test methods and practices for material selection & mix design.
    (d) Performance prediction of HMA.

    2 Asphalt Binder Content (Pb): the percent by weight of asphalt binder in the total mixture.

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    3 Initial Trial Asphalt Binder (Pbi): the percent by weight of the asphalt binder in the total

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    mixture for each trial blend in the selection of the Design Aggregate Structure (DAS).

    4 Bulk Specific Gravity (G1, 2, to n; Gsb, Gmb): the ratio of the weight in air of a unit volume

    ta
    of a permeable material (including both permeable and impermeable voids connected to
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    the surface of the aggregate particle) at a stated temperature relative to the weight in air of
    an equal volume of gas-free distilled water at the stated temperature. This definition
    generally applies to individual aggregate stockpiles (Gl through Gn), the blended
    as

    aggregate (Gsb, AASHTO T84, T85 and T100) or the compacted mix (Gmb, AASHTO T166 or
    T275).
    se

    5 Effective Binder Content (Pbe): the volume of the asphalt binder that is not absorbed into
    er

    the aggregate but remains in the mixture to coat the aggregate particles.
    ov

    6 Effective Specific Gravity (Gse): the ratio of the weight in air of a unit volume of a
    permeable material (excluding voids permeable to binder) at a stated temperature relative to
    the weight in air of an equal volume of gas-free distilled water at the stated temperature.
    ito

    7 Maximum Specific Gravity (Gmm): the ratio of the weight of a given volume of voidless
    et

    (Va=0) loose HMA at a stated temperature (usually 77 F (25C)) to a weight of an equal


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    volume of gas-free distilled water at the same temperature (AASHTO T209).

    8 Voids in Mineral Aggregate (VMA): It is the total space between the aggregate particles
    in the compacted paving mixture which includes 1) the air voids (Va) and 2) the effective
    binder volume . The VMA is defined as the volume of void space between the aggregate
    particles before adding the binder. Note: mineral aggregate is the aggregate which does not
    include any or organic material but it is the material that consists of minerals and compounds
    such as calcium, silicon, etc .

    9 Air Voids (Va): The total volume of the small pockets of air between the coated aggregate
    particles throughout a compacted paving mixture, expressed as percent of the bulk
    volume of the compacted paving mixture.

    10 Voids Filled with Asphalt (VFA): the percentage portion of the volume of intergranular void
    space between the aggregate particles (i.e. VMA) that is occupied by the effective asphalt
    binder volume. It is expressed as the ratio of (VMA-Va) to the VMA.
    QCS 2014 Section 06: Roadworks Page 43
    Part 05: Asphalt Works

    11 Volume of Absorbed Binder (Vba): the volume of binder absorbed into the aggregate (equal
    to the difference in aggregate volume when calculate with the bulk specific gravity and
    effective specific gravity).

    12 Dust to Binder Ratio (P0.075/Pbe): ratio by weight of the percentage of the aggregate
    passing the 0.075 mm sieve (P200) to the effective binder content (Pbe).

    13 Standard Axle: is 8.2 ton (18,000 lb) single axle with dual wheels; the center to center
    distance of dual wheels is 34.29 cm (13.5 in); the tire pressure is 0.517 MPa (75 psi).

    14 ESAL's: is an abbreviation of Equivalent Single Axle Load. The equivalency factor is the
    number of repetition of the standard axle required to induce the same damage as the given
    axle. AASHTO Road Test has shown that an equivalent number of the standard axle
    can represent the damaging effect of the passage of an axle of any mass. This means that

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    the ESAL is the number of applications of the standard axle that is equivalent in the damage

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    to the pavement to an axle of any mass. The relationship is non-linear and is a fourth
    degree. For example, one application of a 16.2 ton single axle (36,000 lb twice as the

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    standard axel) was found to cause damage equal to approximately sixteen applications of
    the standard axle; or one application of a 16.2 tons axle were required to cause the same
    damage or reduction in the pavement serviceability as sixteen applications of the
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    standard axle. Also, one application of a 5.47 ton single axle (12,000 lb two thirds of the
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    standard axel) was found to cause damage equal to approximately 0.2 applications of the
    standard axle; or five applications of a 5.47 tons axle were required to cause the same
    damage or reduction in the pavement serviceability as one applications of the standard
    as

    axle.
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    15 Standard Sieves: Superpave standard sieve sizes are 50.0, 37.5, 25.0, 19.0, 12.5, 9.5,
    4.75, 2.36, 1.18, 0.6, 0.3, 0.15 and 0.075 mm
    er

    16 Maximum Aggregate Size (MS): one standard size larger than the nominal maximum
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    aggregate size (This definition applies only to Superpave mix design.)


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    17 Nominal maximum aggregate size (NMAS): one standard size larger than the first sieve
    that retains more than 10 percent of the aggregate (this definition applies only to Superpave
    et

    mix design).
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    18 Nini, Ndes and Nmax: These are the number of gyrations of the gyratory compactor at
    three compaction levels simulating the construction traffic for N ini, the design traffic for Ndes
    and the maximum anticipated densification by the highest traffic for Nmax

    19 Design Aggregate Structure (DAS): the aggregate blend meeting all Superpave
    requirements.

    20 Design Asphalt Content (DAC): the percent by weight of the asphalt binder in the total mix
    selected at 4.0 % air voids in the mix meeting all Superpave requirements.

    21 ePAVE3: is a user-friendly menu driven Excel program for the Superpave mix design
    system. It is a decision making program that includes all the computations, requirements
    and comparisons to design hot mix asphalt for a given project. ePAVE3 includes Superpave
    requirements based on the latest (to date) Asphalt Institute Superpave Mix Design
    Superpave Series No. 2 (SP-2), third Edition 2001 and last edition of AASTO 2005
    including M323 specification "Standard Practice for Designing Superpave HMA", and R35.
    QCS 2014 Section 06: Roadworks Page 44
    Part 05: Asphalt Works

    22 Polymer: An organic substance that is originated from petroleum gases. It is the product of
    a complicated chemical process. The word polymer originally consists of two words
    poly which means numerous and meros which means parts; therefore, polymer means
    the substance with many parts. Polymers can be either copolymers or homopolymers. The
    most common polymers that are used to modify the asphalt binder for road applications are
    either Elastomers such as SBS or Plastomers such as EVA and Polyethylene.

    23 Neat and Polymer Modified Binder (PMB): neat binder is a black or dark brown material
    produced from refining of petroleum oil in petroleum refineries. The polymer modified binder
    is a neat binder that has been modified by the addition of polymers. The purpose of blending
    polymer and other chemical substances is to improve the neat binder Rheological properties
    to achieve the Performance Grade (PG) requirements of Superpave grading system. This
    process is complicated and involves accurate control of the process parameters such as
    mixing mechanism, temperature, time, concentration and blending details

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    1.2 INTRODUCTION

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    1 This guide, which is based on ref. 1, should be considered as a guide to assist Engineers,
    consultants and contractors to design Hot-Mix Asphalt (HMA) using Superpave system. It is

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    the contractor full responsibility to select the applicable parameters for his project in liaison
    with the Engineer and LSA. This system was developed using the last editions of the Asphalt
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    institute Superpave Mix Design, 2001, and AASHTO, 2005.

    1.3 SUPERPAVE DESIGN PARAMETERS


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    1 Before starting any HMA design using Superpave system for any project, the mixture and
    se

    materials specifications and requirement must be identified. Superpave mix design system
    requires three parameters in order to design a mix. These Parameters are:
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    (a) Expected traffic volume in the project.


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    (b) Nominal Maximum Aggregate Size (NMAS).


    (c) Location of the project.
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    2 The contract documents shall specify and define the design parameters for the project. A
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    brief description of the basic design parameters is given in the following sections.
    m

    1.3.2 Traffic

    1 In Superpave, Traffic is defined as the total anticipated project level equivalent single
    axle load (ESALs) on the design lane for a period of 20 years. To simplify the design
    process, traffic class designations for each ESALs that appears in the Superpave system is
    specified herein. If the contract documents do not specify the ESALs applicable to the
    project, the Engineer can use the information provided in Table 1 to select the traffic classes
    needed to establish Superpave criteria.
    QCS 2014 Section 06: Roadworks Page 45
    Part 05: Asphalt Works

    Table 1
    ESAL and Traffic Designation

    Class Designation ESALs Range Applications

    Agricultural roads with light traffic , local


    VL Very Light Less than 300,000
    and city streets without trucks

    L Light 300,000 to 3 million Agriculture, Feeder and collector roads

    M Medium 3 million to 10 million Main roads and city streets

    H Heavy 10 million to 30 million Highways and Expressway

    Heavily trafficked highways, industrial

    .
    VH Very Heavy More than 30 million
    areas ...

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    1.3.3 Nominal Maximum Aggregate Size (NMAS)

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    1 Six Nominal Maximum Aggregate Sizes (NMAS) are identified in the Superpave system;
    these are 37.5, 25.0, 19.0, 12.5, 9.5 and, 4.75 mm as specified in Table 2.
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    Table 2
    SUAERPAVE Standard NMAS mixtures
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    Nominal Maximum Size Maximum Size


    (NMAS) (MS)
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    37.5 mm 50.0 mm
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    25.0 mm 37.5 mm
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    19.0 mm 25.0 mm

    12.5 mm 19.0 mm
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    9.5 mm 12.5 mm
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    4.75 mm 9.5 mm
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    2 The selection of design NMAS for a specific layer is based on the general rule that the
    NMAS does not exceed half to one-third (1/2 to 1/3) the layer thickness. If the
    contract documents do not specify the NMAS for the project, the Engineer can use the above
    criteria and the information provided in Table 3 to select the NMAS of the project.

    Table3
    Recommended NMAS for Different Layer Types

    Layer Recommended NMAS

    Sand Mix 4.75 mm

    Wearing coarse 9.5 or 12.5 or 19.0 mm

    Base coarse 25.0 or 37.5 mm


    QCS 2014 Section 06: Roadworks Page 46
    Part 05: Asphalt Works

    1.4 SELECTION OF HMA PROPERTIES & REQUIREMENTS

    1 Based on the specified design parameters (Traffic in ESAL, NMAS, geographic


    location of the project and location of required layer to be designed), the mixture properties
    and requirements can be selected. These properties include compaction level, which can be
    identified from Table 4 and the properties of HMA, which can be identified from Table 5.

    Table 4
    Superpave Gyratory Compactive Effort (SGCE)

    Traffic Gyrations
    (ESAL, million) Nini Ndes Nmax

    VL (< 0.3) 6 50 75

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    L (0.3 to 3) 7 75 115

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    M to H (3 to < 30) 8 100 160

    VH (> 30) 9
    ta 125 205
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    Table 5
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    Superpave Criteria for the Mixture Design

    Traffic Class Designation (or ESAL,


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    Criteria million)
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    VL L M H VH
    Ninitial < 91.5 < 90.5 < 89.0
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    Ndesign 96.0
    Required Density (% Gmm)
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    Nmax < 98.0


    37.5 11.0 %
    et

    Voids in the Mineral 25.0 12.0 %


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    Aggregate (VMA %min) Nominal


    Maximum 19.0 13.0 %
    Important Note: mixtures Size, mm
    with VMA greater than 2.0% 12.5
    above the minimum should 14.0 %
    be avoided. 9.5 15.0 %
    4.75 16.0%
    37.5 64-80 64-78 64-75

    25.0 67-80 65-78 65-75

    19.0 70-80 65-78 65-75


    Voids Filled with Asphalt, %
    12.5 70-80 65-78 65-75

    9.5 70-80 65-78 65-75

    4.75 70-80 65-78 65-75


    QCS 2014 Section 06: Roadworks Page 47
    Part 05: Asphalt Works

    Traffic Class Designation (or ESAL,


    Criteria million)

    VL L M H VH

    Dust Proportion (DP) Ratio, if gradation line is For all NMAS DP = 0.6 - 1.2, for NMAS 4.75
    above the PCS DP = 0.9 - 2.0

    Dust Proportion (DP) Ratio, if gradation line is 0.8 1.6


    below the PCS.

    Average Indirect Tensile Strength of the Dry Set Report


    in the Moisture Sensitivity Evaluation, kPa

    1.5 OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS

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    1 According to SP-2 and AASHTO R 35, there are four major steps in the volumetric mix
    design process. These steps consist of

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    (a) Material Selection, (Type of binder and aggregate).
    (b)
    (c)
    Selection of Design Aggregate Structure (DAS).
    Selection of Design Asphalt Content (DAC). ta
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    (d) Evaluation of Strength and Moisture Sensitivity of the Mix.
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    Step 4:
    Strength and Moisture Sensitivity
    Evaluation
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    Step 3:
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    Selection of DAC
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    Step 2:
    Selection of DAS
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    Step 1:
    Selection of Materials
    (Binder, Aggregate and Modifiers)

    2 ePAVE3 program should be used to assist in the preparation of the mix design and obtain the
    mix deign report summarizing the computations and test results. ePAVE3 mix design report
    shall be submitted to the Engineer for acceptance then to LSA for approval.

    1.5.2 Step1: Selection of Materials

    1 This process includes the selection of the asphalt binder PG (ABPG) and the aggregates that
    meet all Superpave criteria.
    QCS 2014 Section 06: Roadworks Page 48
    Part 05: Asphalt Works

    2 The selection of ABPG necessitates an understanding of the climatic condition (e.g.,


    temperature) in which the pavement will be constructed and operated. This includes both
    the average seven-day maximum high temperature and the single-day minimum low
    temperature for the last twenty years and the latitude for that particular geographic location.

    3 To account for traffic volume and speed or both, adjustments should be made to the selected
    ABPG using AASHTO M332.

    4 The requirements of the aggregate are selected based on the anticipated traffic and position
    of the layer within the pavement. The quality criteria for Superpave aggregates are
    summarized in Table 6. In order to be used in Superpave mixtures, the aggregate blends
    must meet two sets of criteria known as source properties and consensus properties. Source
    property requirements apply to each aggregate stockpile, but consensus properties apply
    to the combined blend of multiple stockpiles. The consensus properties are mandatory
    for all Superpave aggregate blends while; source properties are left to the contracts.

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    (a) Consensus Properties (Superpave Requirements):

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    i. Coarse Aggregate Angularity, (CAA) ASTM D5821
    ii. Fine Aggregate Angularity, (FAA) AASHTO T304-Method A
    iii. Flat and Elongated Particles (F&E) ASTM D4791
    iv. Sand Equivalent, (SE)
    ta AASHTO T176
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    (b) Source Properties (QCS Requirements):

    QCS General Specifications, source properties are considered specific to the geology
    as

    of a particular region and the experience with local materials.


    i. Toughness AASHTO T96
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    ii. Soundness AASHTO T104


    iii. Clay lumps & friable particles AASHTO T112
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    iv. Others.
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    Table 6
    Superpave Criteria for Aggregate Consensus Properties
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    Traffic Class Designation (or ESAL, million) Layer Depth,


    Property
    mm
    et

    VH(>30) H(10to<30) M (3 to<10) L (0.3 to 3) VL (< 0.3)

    100/100 95/90 85/80 75/- 55/- < 100 mm CAA, %


    m

    min.
    100/100 80/75 60/- 50/- -/- > 100 mm

    45 45 45 40 - < 100 mm FAA, %


    min.
    45 40 40 40 - > 100 mm

    50 45 45 40 40 SE, % min

    10 10 10 10 - F&E, % max

    Note: CAA values (X/Y) denotes that X% of the coarse aggregate has one fractured face and Y%
    has two or more fractured faces

    1.5.3 Step2: Selection of a Design Aggregate Structure (DAS)

    1 Once a group of aggregates has been identified, these aggregates are combined at
    different percentages to produce at least three distinct blends conforming to Superpave
    gradation requirements presented in Table 7 according to designed NMAS.
    QCS 2014 Section 06: Roadworks Page 49
    Part 05: Asphalt Works

    Table 7
    Aggregate Gradation Requirements Control Points

    Nominal Maximum Aggregate Size, mm - Control Point (Percent Passing)

    Sieve Size 37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm

    Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.

    50.0 mm 100 - - - - - - - - - - -

    37.5 mm 90 100 100 - - - - - - - - -

    25.0 mm - 90 90 100 100 - - - - - - -

    19.0 mm - - - 90 90 100 100 - - - - -

    12.5 mm - - - - - 90 90 100 100 - 100 -

    l .
    9.5 mm - - - - - - - 90 90 100 95 100

    .l.
    4.75 mm - - - - - - - - - 90 90 100

    rw
    2.36 mm 15 41 19 45 23 49 28 58 32 67 - -

    1.18 - - - - - - - - - - 30 60

    0.075 mm 0 6 1 7 2 8 2ta 10 2 10 6 12
    qa
    2 Primary Control Sieve (PCS) shown in Table 8 can be used to determine if the nominated
    blend is fine or coarse gradation. If the gradation line passes below the PCS, it is considered
    as

    as coarse graded and it is considered fine gradation if the line passes above the PCS.
    se

    Table 8
    Gradation Classification - PCS Control Points
    er

    9.5mm 12.5mm 19mm 25mm 37.5 mm Nominal Maximum Size


    ov

    2.36mm 2.36mm 4.75mm 4.75mm 9.5mm Primary Control Sieve Size


    ito

    47% 39% 47% 40% 47% %Passing PCS

    3 Typically, three blends are developed ranging from the coarse to the fine side of the
    et

    Superpave control points for a given nominal maximum size (note: control points and PCS
    m

    differ for different NMAS). After selecting a blend (i.e. from the three trial blends), the
    aggregate consensuses properties must be confirmed to meeting Superpave criteria by
    actual testing.

    4 The most difficult part of designing an aggregate structure is the creation of the VMA
    necessary to meet the volumetric criteria. The procedure is typically a trial and error
    process; however, there are some general guidelines that will assist in obtaining the
    VMA. The following recommendations may be tried to increase VMA:

    (a) Move the gradation away from the maximum density line;
    (b) Use highly angular particles;
    (c) Use particles with a rough surface texture;
    (d) Reduce the percent of natural sand and use more percent of the crushed sand;
    (e) Reduce the amount of P200 used in the HMA; and
    QCS 2014 Section 06: Roadworks Page 50
    Part 05: Asphalt Works

    (f) Use S-shaped gradation curve.

    5 A good design aggregate structure is one that is economical and meets Superpave
    volumetric criteria.

    1.5.4 Work Instructions of Step 2 Selection of DAS

    1 To select the design aggregate structure, do the following:

    (a) Obtain representative hot bin specimens from the plant.


    (b) Determine the consensus properties, water absorption, bulk and apparent specific
    gravities for each aggregate fraction.
    (c) Grade the specimens using Superpave standard sieve set.
    (d) Input the values from two and three into ePAVE3 or combine manually. to

    l .
    develop three blends that meet the Superpave criteria (i.e. within the control points for

    .l.
    the design NMAS)

    rw
    (e) Estimate the initial trial asphalt binder content using ePAVE3 or by using formulas
    presented in ASSHTO R35.
    (f)
    ta
    For unmodified asphalt binders, determine the mixing and compacting temperature for
    the proposed asphalt binder as follows:
    qa
    (i) Measure the rotational viscosity using AASHTO T316 or ASTM D4402 at 135 C
    as

    and 165 C.
    (ii) Input the measured viscosities into ePAVE3. ePAVE3 will generate the viscosity-
    se

    temperature relationship.
    (iii) From the graph, determine:
    er

    2 The mixing temperature at a rotational viscosity of 0.17 0.02 Pa.s.


    ov

    3 The compaction temperature at a rotational viscosity of 0.28 0.03 Pa.s.


    (g) For modified asphalt binders, determine the mixing and compaction temperature in
    ito

    accordance with one of the methods presented in NCHRP 648.


    et

    (h) Prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimens and
    two specimens to measure the Maximum Specific Gravity (Gmm) for each blend at the
    m

    estimated initial trial asphalt content.


    Note: small specimen size of 100 mm is used for mixes having NMAS of 19.0 mm or below.

    (i) Leave the mix in the oven for two hours at the compaction temperature then
    compact two 150.0 mm (or 100 mm) specimens for each blend using the Superpave
    Gyratory Compactor (SGC) to Ndes according to AASHTO T312 (minimum number of
    specimens is six).
    (j) For the specimens that were compacted to Ndes, measure the bulk specific gravity
    (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
    that is automatically recording the specimen height for each gyration.
    (k) Measure the Maximum Specific Gravity (Gmm) for two specimens for each blend
    according to ASSHTO T209.
    (l) Input the measured values into ePAVE3. ePAVE3 will perform the computations,
    display results, and check them against the criteria of the project.
    QCS 2014 Section 06: Roadworks Page 51
    Part 05: Asphalt Works

    (m) Check the results given by ePAVE3 for the three blends and select the most
    conforming blend as the DAS; in case none of the three blends meets Superpave
    criteria, repeat the design by developing additional aggregate blends from the same
    source ; if the criteria is not met change the sources.

    2 Preparation of the binder and aggregate mixtures for the gyratory compactor (SGC) should
    be timed such that a minimum of 20 minutes is allowed between batches. Batched
    specimens should be conditioned in a closed draft oven for a minimum of 2 hours 5
    minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The
    short time oven aging is performed to permit time for the aggregate to absorb the
    binder. All specimens including those for SGC and maximum specific gravity tests, should
    be cured the same amount of time.

    1.5.5 Step 3: Selection of the Design Asphalt Content

    l .
    1 The selected aggregate blend (DAS) will then be mixed with four different proportions of the

    .l.
    binder as follows:

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    (a) Estimated asphalt binder content corrected to give 4.0% air voids.
    (b) Estimated asphalt binder content corrected to give 4.0% air voids minus 0.5 %.
    (c) ta
    Estimated asphalt binder content corrected to give 4.0% air voids plus 0.5 %.
    qa
    (d) Estimated asphalt binder content corrected to give 4.0% air voids plus 1.0 %.

    2 A sufficient amount of the proposed aggregate blend will need to be prepared to


    as

    permit two specimens to be compacted in the SGC according to Superpave system for
    gyrations equal (Ndes), and the maximum specific gravity to be determined at each of the
    se

    four binder contents.


    er

    3 Preparation of the binder and aggregate mixtures for the SGC specimens should be timed
    ov

    such that a minimum of 20 minutes is allowed between batches. Batched specimens should
    be conditioned in a closed draft oven for a minimum of 2 hours 5 minutes prior to
    compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven
    ito

    aging is performed to permit time for the aggregate to absorb the binder. All
    specimens including those for SGC and maximum specific gravity tests, should be cured the
    et

    same amount of time.


    m

    4 The procedure used for design in the laboratory will need to closely match the field conditions
    at the time of construction. Failure to consistently test the materials at the same time interval
    may result in a highly erratic all specific gravity values and possibly failure to achieve the
    required VMA. After the necessary testing has been accomplished, the calculation of the
    volumetric parameters can begin. The averaged results of the various volumetric calculations
    need to be plotted relative to the corresponding binder content. The design binder content is
    selected as that which satisfies the specified volumetric criteria at 4 percent air voids (refer to
    AASHTO R35 for more details).
    QCS 2014 Section 06: Roadworks Page 52
    Part 05: Asphalt Works

    1.5.6 Work Instruction of Step 3- Selection of DAC

    1 To select the deign asphalt content, do the following:

    (a) After selecting the most conforming blend (DAS) from step 2, prepare enough
    hot mix to make two 150 mm (or 100 mm) gyratory specimen and two specimens to
    measure the Maximum Specific Gravity (Gmm) for four trial mixes using DAS of the
    selected blend and four asphalt binder levels as specified in item (5.5.4) herein.
    (b) Compact two 150.0 mm (or 100 mm) specimens for each mix using the Superpave
    Gyratory compactor to Ndes according to AASHTO T312 (total number of specimens
    are eight)
    (c) For the specimens that were compacted to Ndes, measure the bulk specific gravity
    (Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
    that is automatically recording the specimen height for each gyration.

    l .
    .l.
    (d) Input the measured values into ePAVE3. The program will perform all calculations,
    produce the results and compare the results with required mix design properties for the

    rw
    project.
    (e) ePAVE3 will generate the design curves, these are:
    (i) % air voids vs. asphalt content.
    ta
    qa
    (ii) % VMA vs. asphalt content.
    (iii) % VFA vs. asphalt content.
    as

    (iv) % Gmm at Nini vs. asphalt content.


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    (f) From the percentage, air voids vs. asphalt content curve determine the design asphalt
    content (DAC) which corresponds to 4.0 % air voids.
    er

    (g) Use the %VMA vs. asphalt content, %VFA vs. asphalt content % and %Gmm vs.
    ov

    asphalt content graphs to obtain the VMA, FVA and the % Gmm @ Nini values at the
    design asphalt content.
    ito

    (h) Input the DAC, %VMA, %VFA % and Gmm @ Nini into the appropriate cells in
    ePAVE3. ePAVE3 will perform the computations, display results, and check them
    et

    against the criteria of the project.


    m

    (i) If the mix properties at the design asphalt content conform to the Superpave criteria
    then go to the Nmax verification; if not then analyze, evaluate and modify the
    design as needed until the mix properties at the design asphalt content (DAC)
    conform to the criteria.

    1.5.7 Nmax and Ndes Verification

    1 After conforming to Superpave criteria, then do the Nmax verification as follows:

    (a) Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
    design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
    specimens and two Gmm specimens.
    (b) Compact the specimens to Nmax using the gyratory compactor according to AASHTO
    T312.
    (c) Measure the Gmb at Nmax for the two specimens that were prepared using SGC and
    measure the Gmm.
    QCS 2014 Section 06: Roadworks Page 53
    Part 05: Asphalt Works

    (d) Input the values into ePAVE3, which will perform the computations, provide the results,
    and compare them with the Superpave criteria.
    (e) Check the results of ePAVE3, if acceptable then the design is concluded if not
    then redesign the mix.

    2 After conforming that the mix properties at Nmax meet Superpave criteria, then do the Ndes
    verification as follows:

    (a) Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
    design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
    specimens and two Gmm specimens.
    (b) Compact the specimens to Ndes using the gyratory compactor according to AASHTO
    T312.

    .
    (c) Measure the Gmb at Ndes for the two specimens that were prepared using SGC and

    l
    .l.
    use the Gmm from the previous step. Obtain the specimen height at Ndes and Nini from
    the gyratory compactor that is automatically recording the specimen height for each

    rw
    gyration.
    (d) Input the values into ePAVE3, which will perform the computations, provide the results,
    and compare them with the Superpave criteria.
    ta
    qa
    (e) Check the results of ePAVE3, if acceptable then the design is concluded if not
    then redesign the mix.
    as

    1.5.8 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture
    se

    1 The identification of the combination of a design aggregate structure and design binder
    content is now complete. The mixture now needs to demonstrate that it is capable of
    er

    resisting the moisture induced damage. This evaluation is performed in accordance with
    AASHTO T283.
    ov

    2 Moisture sensitivity evaluation requires that a total of six specimens consisting of the
    proposed aggregate blend and binder at the design binder content, be prepared and
    ito

    compacted to approximately 7 0.5% air voids. This group of specimens is divided into
    two subsets with three of the specimens being identified as the control specimens and
    et

    the other three being identified as conditioned specimens.


    m

    3 At the end of the conditioning period all of the specimens are loaded to failure in indirect
    tension. Report the average Indirect Tensile Strength (IDT) of the dry subset in the mix
    design report (see Table 5); and if the ratio of the average strength of the conditioned subset
    to the control subset (retained strength) is more than or equal to 80% , then the mixture
    passes the test. If the retained strength is less than 80%, then the mixture fails. The retained
    strength can be increased by substituting part of the material finer than 0.075 mm by
    mineral admixtures or by using chemical anti-stripping agents. Prepare another six (6)
    specimens and test them as previously described. If this procedure does not improve the
    retained strength to more than 80%, then the design process should be repeated using
    different source.
    QCS 2014 Section 06: Roadworks Page 54
    Part 05: Asphalt Works

    1.5.9 Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity

    1 To check the Strength and the moisture sensitivity of the designed mix, do the following:

    (a) Prepare enough hot mix to make six 150 mm (or 100 mm) gyratory compactor
    specimens using the selected gradation (DAS) and the design asphalt content (DAC).
    (b) Use the Nmax verification densification data to identify the number of gyrations required
    to achieve 7.0 0.5% % air voids (i.e. %Gmm = 92.5 to 93.5 %).
    (c) Compact six 150.0 mm (or 100 mm) specimens using the Superpave Gyratory
    Compactor according to AASHTO T312 compactor (total number of specimens are
    six) to a number of gyrations that will provide approximately 7.0 0.5 % air voids.
    (d) Use ASSHTO T283 to test the six specimens.
    (e) Input the measured values into ePAVE3. ePAVE3 will perform the computations and

    l .
    .l.
    provide the results and compare them with the Superpave criteria
    (f) Check the results given by ePAVE3. Report the average IDT of the Dry group in the

    rw
    mix design report (see Table 5). If the ratio of the average IDT of the conditioned
    subset to the control subset is 80% or more, then the mixture passes the test if not

    ta
    consider redesigning the mix and use some additives.
    qa
    1.6 JOB MIX DESIGN PROPOSAL

    1 A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and submitted to
    as

    the Engineer and LSA for approval. The JMF shall be prepared by the Contractor in precise
    compliance with Superpave system. The Contractor shall select his sources of aggregate
    se

    and bituminous material and, after sufficient quantities have been stockpiled or are available
    for use, obtain representative specimens of the materials and test to determine if they
    er

    conform to the requirements of the specifications.


    ov

    2 Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
    Engineer, detailed information for each mix which he proposes to furnish. The information
    ito

    shall include, but not be limited to the following:

    (a) Copy of mix certificate approval obtained from LSA.


    et

    (b) The source(s) of the aggregate for each mix.


    m

    (c) Pertinent test data and a written certification that the aggregates conform to all of the
    quality requirements specified herein and in section 5.2.
    (d) Type of Asphalt modifier intended to be used in the project. The Asphalt binder
    modifier shall be an approved modifier; along with the Certificate of Conformity of the
    modified asphalt binder to the required grade according to the Superpave Performance
    Based Grading System.
    (e) Pertinent test data on the type and properties of the asphalt binder, modified asphalt
    binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
    (f) Superpave mix design report in ePAVE3 format.
    (g) The type and location of plant to be used for mixing each mix.
    QCS 2014 Section 06: Roadworks Page 55
    Part 05: Asphalt Works

    (h) Type of Asphalt modifier intended to be used in the project. The Asphalt binder
    modifier shall be an approved modifier; along with the Certificate of Conformity of the
    modified asphalt binder to the required grade according to the Superpave Performance
    Based Grading System.
    (i) Pertinent test data on the type and properties of the asphalt binder, modified asphalt
    binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
    (j) Superpave mix design report in ePAVE3 format.
    (k) The type and location of plant to be used for mixing each mix.
    (l) The proposed beginning date for producing bituminous concrete mixtures.
    (m) Any other support data and information special to the project (e.g. technical data
    sheets of a polymer in case it was used).

    .
    3 The Engineer shall be provided access to the materials sampling and testing operations at all

    l
    .l.
    times.

    rw
    4 At the same time that the above information is provided, the Engineer shall obtain one
    hundred (100) kilogram specimens of each individual aggregate size, eight (8) liters of

    ta
    bituminous material and, when used, sufficient quantities of the mineral filler and the
    chemical admixture/asphalt modifier to complete two (2) proposed mix design checks,
    qa
    all representing the materials which the Contractor proposes to furnish. The final job
    mix formula shall be made by using hot-bins aggregate.
    as

    1.6.2 Acceptance of Job Mix Formula


    se

    1 The Engineer shall review the JMF to determine that it contains all required information. If it
    does not contain all required information, it shall be returned within seven (7) days to the
    er

    Contractor for further action and resubmission by the Contractor.


    ov

    2 If the proposed JMF contains all required information but fails to meet all of the requirements
    specified, it shall not be accepted by the Engineer and will be returned to the Contractor
    o

    within fourteen (14) days. The Contractor shall prepare and submit to the Engineer a new
    it

    JMF conforming to the requirements specified and propose a new date for beginning
    et

    production of the bituminous mixtures.


    m

    3 When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all the
    requirements of the specifications, he shall order the Contractor to construct a minimum of
    two hundred (200) meter long field test strip; but, not exceeding one day's production. The
    test strip is used for three purposes:

    (a) To check the contractor ability to produce the approved mix within tolerances.
    (b) To check the contractor ability to construct and compact the mix to satisfy job
    specifications.
    (c) To check the riding quality according to project specifications.

    4 The Engineer shall evaluate the test strip as to its constructability and compactability and the
    mix for conformance to the laboratory tested JMF within the tolerances listed in Table 9. Five
    (5) specimens shall be obtained from the test strip and tested.

    5 If the Engineer is not satisfied with the results of the test strip, he shall state his
    objections in writing and request a revised JMF and a new test strip.
    QCS 2014 Section 06: Roadworks Page 56
    Part 05: Asphalt Works

    6 When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all
    requirements of the specifications and the test strip results are acceptable, he will issue
    written acceptance to the Contractor to begin producing the proposed mixes. Production of
    bituminous concrete mixtures shall not begin until the Engineer has given written acceptance
    of the Job Mix Formula.

    7 Acceptance of the JMF by the Engineer does not relieve the Contractor of his obligation to
    produce bituminous concrete mixtures conforming to all specified requirements.

    1.6.3 Construction Quality Control:

    1 Testing to control the quality of bituminous concrete mixtures produced shall be the
    responsibility of the Contractor.

    2 For each class of bituminous concrete produced and each day's production, the Contractor

    l.
    shall perform one (1) complete Superpave analysis at Ndes including gradation and asphalt

    .l.
    binder content, air voids, %VMA, %VFA, DP ratio, Indirect tensile strength on a specimen

    rw
    obtained from the discharge gate or hauling vehicle. In addition, the Contractor shall
    evaluate on a weekly basis the strength and moisture sensitivity of the mix from a specimen
    obtained from the discharge gate or hauling vehicle.

    3 No mixture conditioning is required when ta


    conducting quality control or quality
    qa
    assurance testing on plant-produced mixture.
    as

    Table 9
    se

    Superpave Job Mix Formula Tolerances for HMA Plant Mix


    er

    Mix Composition Property Tolerance Limit


    ov

    Asphalt Binder Content (Pb) 0.40


    o

    Gradation Passing 4.75 mm and Larger Sieves 5


    it

    Gradation Passing 2.36mm to 150m Sieve 4


    et

    Gradation Passing 75m Sieve


    m

    1.2

    Air Voids (Va) 1.3

    Voids in Mineral Aggregate (VMA) 1.5

    Field Density 92 to 94 (%Gmm)


    QCS 2014 Section 06: Roadworks Page 57
    Part 05: Asphalt Works

    1.7 REFERENCES
    1) Hot Asphalt Mix Design System Using Superpave System Detailed in Asphalt Institute
    SP-2 and the AASHTO 2005 Standards MOT Saudi Arabia, 2006.
    2) AASHTO M323: Standard Specification for Superpave Volumetric Mix Design.
    3) (NCHRP) Report 567: Volumetric Requirements for Superpave Mix Design.
    4) (NCHRP) Report 409: Quality Control and Acceptance of Superpave-Designed Hot
    Mix Asphalt.
    5) (NCHRP) Report 539: Aggregate Properties and the Performance of Superpave-
    Designed Hot-Mix Asphalt.
    6) (NCHRP) Report 513: Simple Performance Tester for Superpave Mix Design.
    7) (NCHRP) Report 648: Mixing and Compaction Temperatures of Asphalt Binders in
    Hot-Mix Asphalt.

    l .
    .l.
    8) AASHTO T320: Standard Method of Test for Determining the Permanent Shear Strain
    and Stiffness of Asphalt Mixtures Using the Superpave Shear Tester (SST).

    rw
    9) AASHTO T321: Standard Method of Test for Determining the Fatigue Life of
    Compacted Hot-Mix Asphalt (HMA) Subjected to Repeated Flexural Bending.
    10)
    ta
    AASHTO T322: Standard Method of Test for Determining the Creep Compliance and
    qa
    Strength of Hot-Mix Asphalt (HMA) Using the Indirect Tensile Test Device.
    11) AASHTO T340: Standard Method of Test for Determining the Rutting Susceptibility of
    Hot Mix Asphalt (APA) Using the Asphalt Pavement Analyzer (APA).
    as
    se
    er
    ov
    o

    END OF PART
    it
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    m
    QCS 2014 Section 06: Road Works Page 1
    Part 06: Concrete Road Pavements

    6 CONCRETE ROAD PAVEMENTS .......................................................................... 3


    6.1 GENERAL REQUIREMENTS .................................................................................. 3
    6.1.1 Scope 3
    6.1.2 References 3
    6.1.3 Quality Control of Concrete Strength 4
    6.2 TRIAL LENGTH ....................................................................................................... 5
    6.2.1 General Requirements for Trial Length 5
    6.2.2 Assessment of Trial Length 6
    6.2.3 Approval and Acceptance of Trial Length 7
    6.3 REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE .................................. 7
    6.3.1 Materials and Mix Designs for Pavement Quality Concrete 7
    6.3.2 Workability of Pavement Quality Concrete 7

    .
    6.3.3 Trial Mixes 8

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    .l.
    6.3.4 Separation Membrane 8

    rw
    6.3.5 General Requirements for Steel Reinforcement 8
    6.3.6 Jointed Reinforced Concrete Slabs 9
    6.3.7 Continuously Reinforced Concrete Slabs (CRCP or CRCR) 10
    6.3.8 General Requirements for Transverse Joints ta 10
    qa
    6.3.9 Transverse Contraction Joints 11
    6.3.10 Transverse Expansion Joints 11
    6.3.11 Transverse Warping Joints 11
    as

    6.3.12 Transverse Construction Joints 11


    se

    6.3.13 General Requirements for Longitudinal Joints 12


    6.3.14 Longitudinal Construction Joints 13
    er

    6.3.15 Dowel Bars 13


    6.3.16 Joint Grooves 16
    ov

    6.3.17 Groove Formers and Bottom Crack Inducers 17


    6.3.18 Joint Filler Board 18
    o

    6.3.19 Preparation and Sealing of Joint Grooves 18


    it

    6.3.20 Sealing with Applied Sealants 19


    et

    6.3.21 Sealing with Compression Seals 20


    m

    6.3.22 Joint Seals 21


    6.3.23 Joints at Manhole and Gully Slabs 21
    6.3.24 Inspection of Dowel Bars 22
    6.3.25 Side Forms, Rails and Guide Wires 22
    6.3.26 Delivery, Storage and Batching of Concreting Materials 23
    6.3.27 Mixing Concrete 24
    6.3.28 Transport and Delivery 24
    6.3.29 General Requirements for Construction by Machine 24
    6.3.30 Construction by Fixed Form Paving Machines 25
    6.3.31 Construction by Slip-Form Paving Machine 26
    6.3.32 Construction by Small Paving Machines or Hand Guided Methods 26
    6.3.33 Surface Textures 28
    6.3.34 Strength 29
    6.3.35 Trial Mixes 29
    6.3.36 Trial Length 29
    QCS 2014 Section 06: Road Works Page 2
    Part 06: Concrete Road Pavements

    6.3.37 Surface Finish 30


    6.4 REQUIREMENTS FOR CEMENT BOUND MATERIALS ....................................... 30
    6.4.1 General Requirements for Cement Bound Materials 30
    6.4.2 Batching and Mixing 31
    6.4.3 Transporting 31
    6.4.4 Laying 31
    6.4.5 Compacting 32
    6.4.6 Curing 32
    6.4.7 Preliminary Trial 33
    6.4.8 Cement Bound Material Category 1 (CBM1) 33
    6.4.9 Cement Bound Material Category 2 (CBM2) 34
    6.4.10 Cement Bound Material Category 3 (CBM3) 34
    6.4.11 Cement Bound Material Category 4 (CBM4) 34

    l .
    6.4.12 Testing of Cement Bound Materials 35

    .l.
    6.4.13 Special Requirements for Cement Bound Materials 35

    rw
    ta
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    et
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    QCS 2014 Section 06: Road Works Page 3
    Part 06: Concrete Road Pavements

    6 CONCRETE ROAD PAVEMENTS

    6.1 GENERAL REQUIREMENTS

    6.1.1 Scope

    1 This part of the specification covers the; materials, mix designs, production and laying of
    pavement quality concrete, lean mix concrete and cement bound materials.

    2 Related Sections and Parts are:

    This Section
    Part 3 ............... Earthworks
    Part 4 ............... Unbound Pavement Materials

    .
    Part 5 ............... Asphalt Works

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    Section 5 - Concrete

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    Part 16 ............ Miscellaneous - Pavement Quality Concrete

    6.1.2 References
    ta
    qa
    1 The following standards are referred to in this part of the specification
    BS 1377: Part 9 ..........Methods of testing soils in-situ tests
    as

    BS 1881...................... Methods of testing concrete -


    BS 1924: Part 1 & 2.... Stabilised materials for civil engineering purposes
    se

    BS 2499 & BS EN 14188 Hot applied joint sealants for road pavements
    er

    BS 2752...................... Chloroprene rubber compounds


    BS 3900: Part F12 ...... Determination of resistance to neutral salt spray
    ov

    BS 3963...................... Method for testing the performance of concrete mixers


    BS EN ISO 11600 ...... Two part polysulphide sealants
    o

    BS 4449...................... Reinforcing bars


    it

    BS 4482...................... Cold drawn steel wire for reinforcing concrete


    et

    BS 4483...................... Reinforcing mesh


    m

    BS 5212: Part 1 & 2.... Cold applied joint sealants for concrete pavements
    BS EN 206 & BS 8500 Supply of concrete
    BS 7542...................... Methods for test of curing compounds for concrete
    BS 812........................ Testing methods for aggregates

    ASTM D3406 .............. Specification for joint sealant - hot applied elastomeric types
    ASTM 7116 ................ Specification for joint sealant - hot applied elastomeric types (jet
    fuel resistant)
    ASTM D2628-91......... Specification for preformed joint seals

    DTP ............................ Manual of contract documents for highway works -Volume 1


    specification for highway works
    QCS 2014 Section 06: Road Works Page 4
    Part 06: Concrete Road Pavements

    6.1.3 Quality Control of Concrete Strength

    1 Sampling and testing for, and compliance with the specified characteristics strength of
    designed mixes shall be in accordance with BS EN 206 & BS 8500, except that it shall be at
    the following rates of sampling and testing and meet the following requirements:

    (a) Concrete cubes of the appropriate size shall be made, cured and tested in accordance
    with BS 1881 respectively from concrete delivered to the paving plant, each group
    being from a different delivery of concrete. At least 3 cubes shall be made per group
    2
    for each 600 m of concrete slab and not less than 6 groups shall be made each day,
    2
    for each type of mix. For areas less than 600 m , at least 4 cubes shall be made for
    2
    each 100 m or less. This rate of sampling and testing may be reduced at the
    Engineer's discretion.
    2

    .
    (b) For areas of 600 m or more, one cube shall be tested in compression at 7 days and

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    the other two at 28 days after mixing. Groups of four consecutive results at 28 days
    shall be used for assessing the strength for compliance with BS EN 206 & BS 8500.

    rw
    2
    For areas less than 600 m , two cubes shall be tested at 7 days and two tested at 28
    days and assessed in accordance with BS EN 206 & BS 8500.
    (c) ta
    The ratio R between 7 and 28 day strengths shall be established for the mix to be used
    qa
    in the slab by testing pairs of cubes at each age on at least six batches of the
    proposed mix or it shall be quoted by the supplier of the concrete. The average
    strength of the 7 day pair of cubes shall be divided by the average strength of the 28-
    as

    day pair of cubes for each batch and the ratio R shall be the average of these six
    values. The ratio R shall be expressed to three decimal places.
    se

    (d) If during the construction of the trial length or during normal working, the average value
    er

    of any 4 consecutive 7 day test results falls below the strengths required then the
    cement content of the concrete shall be increased by 5 % by mass or by an amount
    ov

    agreed by the Engineer. The increased cement content shall be maintained at least
    until the four corresponding 28-day tests have been assessed. If the cement content is
    o

    increased, the concrete mix shall be adjusted to maintain the required workability.
    it

    (e) The values in columns 3 and 4 of Table 6.1 may only be used with the permission of
    et

    the Engineer when sufficient test results on trial mixes for calculating the ratio are not
    available. Once sufficient results are available from normal working the ratio R shall be
    m

    calculated from the results available on Site.


    (f) To assess the time for use of a concrete slab by traffic, the strength development rate
    may be predetermined by trial mixes. Alternatively pairs of cubes shall be made for
    2
    each 600 m or less and stored alongside the pavement in containers or in such a way
    that their sides are well insulated. If thermal insulation is used for accelerated curing
    the cubes shall be similarly insulated. Pairs of cubes shall be tested at intervals
    decided by the Engineer. Tests for compliance with the specified strength shall be
    made in the normal way.
    QCS 2014 Section 06: Road Works Page 5
    Part 06: Concrete Road Pavements

    Table 6.1
    7 Day Cube Strength

    All Mixes, R PC Mixes, R not PFA or ggbs mixes, R


    Grade of Concrete 2
    available available not available N/mm

    C40 43R 35 29
    C30 33R 27 22
    C20 22R 18 14
    C15 17R 13 11
    C10 10R 8 7
    C7.5 7R 5.5 4.5

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    rw
    6.2 TRIAL LENGTH

    6.2.1 General Requirements for Trial Length


    ta
    qa
    1 Except in rapid construction projects, at least one month prior to the construction of the trial
    length of surface slabs or CRCR (Continuously Reinforced Concrete Road Base) the
    Contractor shall submit for the Engineer's approval a detailed description of the proposed
    as

    materials, mix proportions, plant, equipment and construction methods.


    se

    2 No trials of new materials, plants, equipment or construction methods; nor any development
    of them shall be permitted either during the construction of the trial length or in any
    er

    subsequent paving work, unless they form part of further approved trials.
    ov

    3 The Contractor shall demonstrate the materials, mix proportions, plant, equipment and
    method of construction that are proposed for concrete paving, by first constructing a trial
    o

    length of slab, at least 150m but not more than 300 m, long for mechanised construction, and
    it

    at least 30m long for hand guided methods, or otherwise as directed by the Engineer.
    et

    4 The mix proportions decided by trial mixes may be adjusted during the trial but shall not be
    m

    changed once the trial length has been approved except with the agreement of the Engineer.

    5 The trial length shall be constructed in two parts over a period comprising at least part of two
    separate working days, with a minimum of half the proposed trial lengths constructed each
    day. The trial length shall be constructed at a similar rate to that which is proposed for the
    main construction in the permanent works.

    6 At least two transverse joints and one longitudinal joint of each type that are proposed for
    unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in
    the permanent works shall be constructed and assessed in the trial length.

    7 If in the trial length expansion joints are not demonstrated, the first 2 expansion joints and at
    least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for hand
    guided method of construction laid in the main construction in the permanent works, shall be
    considered the trial length for these joints.
    QCS 2014 Section 06: Road Works Page 6
    Part 06: Concrete Road Pavements

    8 One construction joint shall be demonstrated in each trial length of CRCP or CRCR.

    6.2.2 Assessment of Trial Length

    1 The trial length shall comply with the Specification in all respects, with the following additions
    and exceptions provided in (a) through (d) below.

    (a) Surface Levels and irregularity


    (i) in checking for compliance the levels shall be taken at intervals of not more than
    2.5 m along any line or lines parallel to the longitudinal centre line of the trial
    length.
    (ii) The maximum number of permitted irregularities of pavement surfaces shall
    comply with the requirements for asphalt pavements as per Part 5
    for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on

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    values for a 300 m length.

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    rw
    (b) Joints
    (i) At least 3 cores of minimum diameter 100 mm shall be taken from the slab at

    ta
    joints to check the lateral and vertical location of joint grooves and bottom crack
    inducers.
    qa
    (ii) After a minimum of 24 hours following construction the removable part of the
    joint groove former shall be taken out and at least three joints and the sides of
    as

    the groove shall be inspected for compaction. If there are voids the size and
    number should be compared with a similar size section of the photograph for 3%
    se

    excess voidage in BS 1881. If there is excess voidage, additional


    compaction shall be provided and further joints inspected. The joints so
    er

    exposed shall be temporarily or permanently sealed


    ov

    (iii) Alignment of dowel bars shall be inspected in any two consecutive transverse
    joints. If the position or alignment of the dowel bars at one of these joints does
    not comply after the next 3 consecutive joints of the same type have been
    o

    inspected then the method of placing dowels shall be deemed to be satisfactory.


    it

    (iv) If there are deficiencies in the first expansion joint constructed as a trial,
    et

    the next expansion joint shall be a trial joint. Should this also be deficient further
    m

    trial expansion joints shall be made as part of a trial length which shall not form
    part of the Permanent Works, unless agreed by the Engineer.
    (c) Density
    (i) Density shall be assessed from at least 3 cores drilled from each part of the trial
    length.
    (d) Position of Reinforcement and Tie Bars
    (i) Compliance for the position of steel reinforcement and for the position and
    alignment of tie bars shall be checked by drilling additional cores from the slab
    unless they can be determined from cores taken for density assessment.
    QCS 2014 Section 06: Road Works Page 7
    Part 06: Concrete Road Pavements

    6.2.3 Approval and Acceptance of Trial Length

    1 Approval of the materials, mix proportions, plant, equipment and construction methods will be
    given when a trial length complies with the specifications. The Contractor shall not proceed
    with normal working until the trial length has been approved and any earlier defective trial
    lengths have been removed, unless they can be remedied to the satisfaction of the Engineer.

    2 When approval has been given, the materials, mix proportions, plant, equipment and
    construction methods shall not thereafter be changed, without the approval of the Engineer
    except for maintenance of plant. Any changes in materials, mix proportions, plant,
    equipment, and construction methods shall entitle the Engineer to require the Contractor to
    lay a further trial length as described in this Clause to demonstrate that these changes will
    not adversely affect the permanent works.

    3 Trial lengths which do not comply with the Specification, with the exception of areas within

    l .
    the pavement surface which can be remedied shall be removed immediately upon notification

    .l.
    of deficiencies by the Engineer and the Contractor shall construct a further trial length.

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    6.3 REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE

    6.3.1
    ta
    Materials and Mix Designs for Pavement Quality Concrete
    qa
    1 The constituent materials and mix designs for pavement quality control shall be as per
    Section 5: Part 16.
    as

    6.3.2 Workability of Pavement Quality Concrete


    se

    1 The workability of the concrete at the point of placing shall enable the concrete to be fully
    er

    compacted and finished without undue flow. The optimum workability for the mix to suit the
    paving plant being used shall be determined by the Contractor and approved by the
    ov

    Engineer.

    2 The workability shall be determined by the compacting factor test, or the Vebe test or
    o

    alternatively for concrete grade C20 or below, by the slump test, all in accordance with BS
    it

    1881, at the minimum rate of one determination per 300 m2 of slab laid or 6 times per day,
    et

    whichever is greater. For areas less than 300 m2 the rate shall be at least one determination
    m

    to each 20 m length of slab or at least 3 times per day.

    3 Alternatively the volumetric method of determining the Compacting Factor in BS 1881 may be
    used. Tests for workability shall be carried out at the point of placing, in conjunction with
    tests for strength and any tests for air content. The workability shall be maintained at the
    optimum within the following tolerances.
    Compacting Factor (CF) +0.03
    Slump +20mm
    Vebe +3 seconds or as agreed by the Engineer as a results of trial
    mixes.
    4 Any alteration to the optimum workability necessitated by a change in conditions shall be
    agreed beforehand by the Engineer.
    QCS 2014 Section 06: Road Works Page 8
    Part 06: Concrete Road Pavements

    5 If any determination of workability gives result outside the tolerance, a further test shall be
    made immediately on the next available load of concrete. The average of the two consecutive
    results and the difference between them shall be calculated. If the average is not within the
    tolerance or the difference is greater than 0.06 for CF or 20 mm for slump, or 6 seconds for
    Vebe or other value agreed with the Engineer, subsequent samples shall be taken from the
    delivery vehicles, which shall not be allowed to discharge into the Works until compliance
    with the Specification has been established.

    6.3.3 Trial Mixes

    1 For concrete grades C15 and above the Contractor shall carry out laboratory trials of
    designed mixes with the materials from all sources to be used in the Works, in accordance
    with BS EN 206 & BS 8500 unless recent data relating entirely to the proposed mix is
    approved by the Engineer.

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    2 The trial mixes shall be repeated if necessary until the proportions of ingredients are
    determined which will produce a concrete which complies in all respects with the

    rw
    Specification.

    3 Apart from minor adjustments to the mix as permitted by BS EN 206 & BS 8500 any changes
    ta
    in sources of materials or mix proportions that are proposed by the Contractor during the
    qa
    course of the Works shall be assessed by making laboratory trial mixes and the construction
    of a further trial length unless otherwise approval is given by the Engineer.
    as

    6.3.4 Separation Membrane


    se

    1 A separation membrane shall be used between jointed reinforced concrete surface slabs or
    unreinforced concrete surface slabs and the sub base.
    er

    2 Separation membranes shall be impermeable plastic sheeting 125 microns thick laid flat
    ov

    without creases. Where an overlap of plastic sheets is necessary, this shall be at least
    300 mm. There shall be no standing water on or under the membrane when the concrete is
    o

    placed upon it.


    it
    et

    3 Under CRCP and CRCR a waterproof membrane shall be provided, which shall be a
    bituminous spray before concreting. Where a bituminous spray has been used to cure
    m

    cement bound material or wet lean concrete then only those areas which have been
    damaged shall be resprayed after making good. The waterproof membrane shall be
    bituminous cutback in accordance with clause 5.12 of this Section.

    6.3.5 General Requirements for Steel Reinforcement

    1 Reinforcement shall comply with any of the following standards and be in prefabricated
    sheets or cages, or bars assembled on site and shall be free from oil, dirt, loose rust and
    scale:

    (a) (Carbon steel bars for the reinforcement of concrete) BS 4449


    (b) (Cold-reduced steel wire for the reinforcement of concrete) BS 4482
    (c) (Steel fabric for the reinforcement of concrete) BS 4483
    QCS 2014 Section 06: Road Works Page 9
    Part 06: Concrete Road Pavements

    (d) When deformed bars are used they shall conform to Type 2 bond classification of BS
    4449.

    2 Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in
    longitudinal bars shall be not less than 35 times bar diameters or 450 mm which ever is
    greater. In continuously reinforced concrete slabs (CRCP or CRCR) only one third of the
    laps may be in any one transverse section, except in single bay width construction where half
    the laps may be in any one transverse section. There shall be a minimum of 1.2 m
    longitudinally between groups of transverse laps or laps in prefabricated reinforcement
    sheets. Alternatively the reinforcement may be butt welded by a process approved by the
    Engineer.

    3 Laps in a transverse reinforcement shall be a minimum of 300 mm. Where prefabricated


    reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is

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    required in the transverse bars within the lap of the longitudinal reinforcement. These

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    transverse bars may be cropped or fabricated shorter so that the requirements for cover are

    rw
    met.

    4 If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal

    ta
    supports and retained in position at the required depth below the finished surface and
    distance from the edge of the slab so as to ensure that the required cover is achieved.
    qa
    Reinforcement assembled on site shall be tied, or firmly fixed, by a procedure agreed with the
    Engineer, at sufficient intersections to provide sufficient rigidity to ensure that the
    as

    reinforcement remains in the correct position during construction of the slab.

    5 Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCR) is constructed in two
    se

    layers, the reinforcement in the form of prefabricated sheets may be placed on or into the
    bottom layer which shall be spread and compacted to such a level that it will support the
    er

    reinforcement without distortion at the required position in the slab. The sheets shall be tied
    ov

    together at overlaps and after the second layer has been spread and compacted, the
    reinforcement shall have the required cover.
    o

    6 When a reinforced concrete slab is constructed at maximum width the transverse


    it

    reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal


    et

    diameter bars at 600 mm centres. This reinforcement shall be at least 600 mm longer than
    m

    one third of the width of the slab and be lapped to other transverse reinforcement bars or
    sheets, or be continuous across the whole width of each slab.

    6.3.6 Jointed Reinforced Concrete Slabs

    1 The reinforcement shall be so placed that after compaction of the concrete, the cover below
    the finished surface of the slab is 50 + 10 mm for slabs less than 200 mm thick, 60 + 10 mm
    for slabs 200 mm or more but less than 270 mm thick and 70+20 mm for slabs 270 mm thick
    or more.

    2 The negative vertical tolerance shall not be permitted beneath road stud recesses.

    3 Where traffic signal detector loops are to be installed, the minimum cover to the
    reinforcement from the surface shall be 100 mm.
    QCS 2014 Section 06: Road Works Page 10
    Part 06: Concrete Road Pavements

    4 The vertical cover between any longitudinal joint groove forming strip and any reinforcement
    or tie bars shall be at a minimum of 30 mm.

    5 Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any
    transverse reinforcement shall terminate at 125+25 mm from the edges of the slab and
    longitudinal joints, where tie bars are used.

    6 No longitudinal bars shall lie within 100 mm of a longitudinal joint. The reinforcement shall
    terminate 300 mm + 50 mm from any transverse joint, excluding emergency construction
    joints.

    6.3.7 Continuously Reinforced Concrete Slabs (CRCP or CRCR)

    .
    1 The reinforcement shall be Grade 460 deformed steel bars as detailed on the Contract

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    Drawings.

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    2 The reinforcement shall consists of bars assembled on site, or of prefabricated sheets.

    3 Except where otherwise shown on the Drawings the longitudinal bars shall be parallel to the
    centre line of the road.
    ta
    qa
    4 The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at
    the mid depth of the specified thickness of the slab + 25 mm. No longitudinal bar shall lie
    as

    within 100mm of a longitudinal joint.


    se

    5 In reinforcement assembled on site, longitudinal bars shall be placed immediately above any
    transverse bars, which shall be at right angles to the longitudinal axis of the carriageway.
    er

    Any transverse reinforcement shall terminate 125+25 mm from the edges of the slab and
    ov

    longitudinal joints where tie bars are used.

    6.3.8 General Requirements for Transverse Joints


    it o

    1 Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and
    et

    shall be contraction, expansion or warping joints at the spacing shown on the Drawings such
    that for unreinforced concrete slabs the length/width ratio shall be not greater than 2.0.
    m

    2 Joints in the surface slab and sub-base shall be staggered so that they are not coincident
    vertically and are at least 1m apart.

    3 Transverse joints shall be straight within the following tolerances along the intended line of
    the joint, which is the straight line transverse to the longitudinal axis of the carriageway at the
    position proposed by the Contractor and agreed by the Engineer, except at road junctions or
    roundabouts where the positions shall be as shown on the Drawings:

    (a) Deviations of the filler board or bottom crack inducer from the intended line of the
    joint shall be not greater than 10 mm.

    (b) The best fit straight line through the joint groove as constructed shall be not more
    than 25 mm from the intended line of the joint.

    (c) Deviations of the joint groove from the best fit straight line of the joint shall be not
    greater than 10 mm.
    QCS 2014 Section 06: Road Works Page 11
    Part 06: Concrete Road Pavements

    (d) When top groove formers and bottom crack inducers are used, the joint groove
    as constructed shall be located vertically above the bottom crack inducer within a
    horizontal tolerance of 25 mm.

    4 Transverse joints on each side of a longitudinal joint shall be in line with each other and of
    the same type and width. The position of the joints relative to manholes and gullies shall be in
    accordance with the Drawings.

    5 Transverse joints shall have a sealing groove which shall be sealed in compliance with
    Clause 6.3.20 of the specification.

    6.3.9 Transverse Contraction Joints

    1 Contraction joints shall consist of:

    .
    (a) Either a sawn joint groove, or

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    (b) a wet formed joint groove and a bottom crack inducer

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    (c) dowel bars
    (d) a sealing groove.

    6.3.10 Transverse Expansion Joints ta


    qa
    1 Expansion joints shall consist of:
    as

    (a) a joint filler board


    se

    (b) dowel bars


    (c) a sealing groove.
    er

    2 The filler board shall be positioned vertically within the prefabricated joint assemblies along
    ov

    the line of the joint and at such depth below the surface as will not impede the passage of the
    finishing beams on the paving machines.
    o

    3 The joint filler board together with the sealing groove shall provide a complete separation of
    it

    adjacent slabs and any spaces around dowel bars and between the sub-base and the filler
    et

    board shall be packed with a suitable compressible material after fixing the joint assembly.
    m

    6.3.11 Transverse Warping Joints

    1 Warping joints shall consist of:

    (a) Either a sawn joint groove, or


    (b) a wet formed joint groove and a bottom crack inducer
    (c) tie bars
    (d) a sealing groove.

    6.3.12 Transverse Construction Joints

    1 Construction joints made at the end of a working day in unreinforced concrete slabs and
    jointed reinforced concrete slabs shall be expansion joints or contraction joints. In the event
    of mechanical breakdown of the concreting machinery, or at the onset of adverse weather,
    emergency joints may be formed.
    QCS 2014 Section 06: Road Works Page 12
    Part 06: Concrete Road Pavements

    2 Emergency joints in unreinforced concrete slabs shall be either contraction or expansion


    joints not less than 2.5 m from the preceding or succeeding joint position.

    3 Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the
    preceding or succeeding joint position. The stop end formwork shall be sufficiently rigid to
    ensure that dowel bars, tie bars or reinforcement will be held in position in compliance with
    the specification, and placed in such a position that it permits the longitudinal reinforcement
    to project through the joint for a distance of at least 750 mm.

    4 Construction joints in continuously reinforced concrete slabs (CRCP and CRCR) in an


    emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement
    without the approval of the Engineer. The stop end formwork shall be sufficiently rigid to
    ensure that the longitudinal reinforcement and the tie bars projecting through the joint are

    .
    held in the correct position.

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    6.3.13 General Requirements for Longitudinal Joints

    rw
    1 Longitudinal joints shall be provided in surface slabs between or at the centre of traffic lanes
    within the allowable positions as shown on the Drawings, so that bay widths are not greater
    ta
    than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with
    qa
    limestone aggregate) for reinforced concrete surface slabs with transverse reinforcement.

    2 Longitudinal joints shall be provided in CRCR between lanes or at the centre of lanes, within
    as

    a tolerance of +150 mm so that bay widths are not greater than 6 m (or 7.6 m with limestone
    se

    aggregate).

    3 Joints in the surface slab, road base or sub-base shall be staggered so that they are not
    er

    coincident vertically and are least 300 mm apart. The positions of all longitudinal joints in any
    ov

    slab shall be agreed by the Engineer prior to construction of the slab.

    4 Wet-formed longitudinal joints shall consists of wet-formed joint grooves, bottom crack
    o

    inducer and tie bars except where transverse reinforcement is permitted in lieu.
    it
    et

    5 Longitudinal joints shall be constructed in the positions agreed by the Engineer within the
    m

    following tolerances:

    (a) Deviations of the bottom crack inducer from the intended line of the joint parallel
    to the axis of the road shall not be greater than +13 m.

    (b) The joint groove shall be located vertically above the bottom crack inducers within
    a horizontal tolerances of +25 mm.

    (c) The best fit line along the constructed joint groove, shall be not more than 25 mm
    from the intended line of the joint.
    (d) Deviations of the joint groove from the best fit line of the joint shall be not greater
    than 10 mm.
    QCS 2014 Section 06: Road Works Page 13
    Part 06: Concrete Road Pavements

    6 Tie bars may be replaced by continuous transverse reinforcement across the joints in
    continuously reinforced concrete slabs, which are constructed in more than one lane width in
    one operation, provided that the transverse reinforcement is a minimum of 12 mm diameter
    bars at 600 mm centres.

    6.3.14 Longitudinal Construction Joints

    1 Longitudinal construction joints between separate slabs shall have tie bars with a joint
    groove. Alternatively, if split forms are used, the transverse reinforcement, if 12 mm diameter
    or more, may be continued across the joint for a minimum of 500 mm or 30 times the
    diameter of the transverse reinforcement bars, whichever is greater.

    2 A joint sealing groove is not required in construction joints in continuously reinforced concrete

    .
    road bases. Where the edge of the concrete slab is damaged it shall be made good to the

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    approval of the Engineer before the adjacent slab is constructed.

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    6.3.15 Dowel Bars

    1 Dowel bars shall be Grade 250 steel complying with BS 4449 and shall be free from oil, dirt,
    ta
    loose rust and scale. They shall be straight, free of burrs and other irregularities and the
    qa
    sliding ends sawn or, if approved by the Engineer, cropped cleanly with no protrusions
    outside the normal diameter of the bar. For expansion joints, dowel bars shall be 25mm
    diameter at 300 mm spacing, 600 mm long for slabs up to 239 mm thick and 32 mm diameter
    as

    for slabs 240 mm thick or more. For contraction joints, dowels shall be 20 mm diameter at
    se

    300 mm spacing 400 mm long for slabs up to 239 mm thick and 25 mm diameter for slabs
    240 mm thick or more.
    er

    2 Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to
    ov

    construction of the slab. For contraction joints, as an alternative to prefabricated assemblies,


    dowel bars may be mechanically inserted with vibration into the concrete by a method which
    o

    shall ensure full recompaction of the concrete around the dowel bars and the surface finished
    it

    by a diagonal finishing beam. Or a longitudinal oscillating float travelling across the slab.
    et

    3 Dowel bars shall be positioned at mid-depth from the surface level of the slab 20 mm.
    m

    They shall be aligned parallel to the finished surface of the slab, to the centre line of the
    carriageway and to each other within the following tolerances:

    (a) for bars supported on cradles prior to construction of the slab and for inserted
    bars in two layers construction prior to placing the top layer:
    (i) All bars in a joint shall be within 3 mm per 300 mm length of bars.
    (ii) Two thirds of the bars shall be within 2 mm per 300 mm length of bar.

    (iii) No bar shall differ in alignment from an adjoining bar by more than 3 mm per
    300 mm length of bar in either the horizontal or vertical plane.

    (b) for all bars, after construction of the slab:


    (i) Twice the tolerances for alignment as in (i) above.
    QCS 2014 Section 06: Road Works Page 14
    Part 06: Concrete Road Pavements

    (ii) Equally positioned about the intended line of the joint within a tolerance of 25
    mm.

    4 Cradles supporting dowel bars shall not extend across the line of the joint.

    5 Dowel bars, supported on cradles in assemblies, when subjected to a load of 110N applied at
    either end and in either the vertical or horizontal direction (upwards and downwards and both
    directions horizontally) shall not deflect more than the following limits:

    6 Two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm
    per 300 mm length of bar.

    7 The remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm
    length of bar.

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    .l.
    8 The assembly of dowel bars and supporting cradles, including the joint filler board in the case
    of expansion joints shall have the following degree of rigidity when fixed in position:

    rw
    9 For expansion joints the deflection of the top edge of the filler board shall be not

    ta
    greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
    face of the joint filler board and distributed over a length of 600 mm by means of
    qa
    a bar or timber packing at mid depth and midway between individual fixings, or
    300 mm from either end of any length of filler board, if a continuous fixing is used.
    as

    The residual deflection after removal of the load shall be not more than 3 mm.
    se

    10 The joint assembly fixings to the sub-base shall not fail under the 1.3kN load
    applied for testing the rigidity of the assembly but shall fail before the load
    er

    reaches 2.6 kN.


    ov

    11 The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail
    before the load reaches 2.6 kN when applied over a length of 600 mm by means
    o

    of a bar or timber packing placed as near to the level of the line of fixings as
    it

    practicable.
    et
    m

    12 Failure of the fixings shall be deemed to be when there is displacement of the


    assemblies by more than 3 mm with any form of fixing, under the test load. The
    displacement shall be measured at the nearest part of the assembly to the centre
    of the bar or timber packing.

    13 Dowel bars shall be covered by a thin plastic sheath over the whole length of the bar. The
    sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The
    sheathed bar shall comply with the following pull out test:
    QCS 2014 Section 06: Road Works Page 15
    Part 06: Concrete Road Pavements

    14 Four bars shall be taken at random from stock and without any special
    preparation shall be covered by sheaths. The dowel bars which have been
    sheathed shall be cast centrally into concrete specimens 150x150x450 mm,
    made of the same mix proportions to be used in the pavement, but with a
    maximum nominal aggregate size of 20 mm and cured in accordance with
    BS 1881. At 7 days a tensile load shall be applied to achieve a movement
    of the bar at least 0.25 mm. The average bond stress to achieve this movement
    shall be not greater than 0.14 N/mm2.

    15 For expansion joints a closely fitting cap 100 mm long consisting of waterproofed cardboard
    or an approved synthetic material shall be placed over one end of each
    dowel bar. An expansion space 10 mm greater than the thickness of the joint filler board shall
    be formed between the end of the cap and the end of the dowel bar.

    l .
    .l.
    16 Tie Bars

    rw
    17 Tie bars in transverse or longitudinal joints shall be Grade 250 steel or Grade 460 deformed
    steel bars complying with BS 4449, in accordance with the requirements given below and

    ta
    Table 6.2. Deformed bars shall have Type 2 bond classification. Tie bars shall be free from
    oil, dirt, loose rust and scale. Tie bars which are to be cranked and later straightened shall be
    qa
    Grade 250.

    18 Tie bars projecting across a longitudinal joint shall be protected from corrosion by a flexible
    as

    polymeric corrosion resistant coating, bonded onto the previously cleaned centre section,
    leaving between 250 mm and 300 mm of each of the bars uncoated.
    se

    19 Where tie bars are cranked for construction joints and later straightened the coating shall be
    er

    shown to be capable of being straightened through 90 degrees without cracking. The coating
    ov

    shall also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS
    3900 : Part F12, without showing any visible cracking, or corrosion of the protected part of
    the bar. Any damage observed on the coating after straightening shall be made good before
    o

    the concrete is placed.


    it
    et

    20 Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid
    assemblies with adequate supports and fixings to remain firmly in position during the
    m

    construction of the slab.

    21 Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from
    above using a method which ensures recompaction of the concrete around the tie bars.

    22 At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted
    into the side of the slab by a method which ensures recompaction of the concrete around the
    tie bars and adequate bond and which shall be approved by the Engineer.

    23 Tie bars shall be positioned and remain within the middle third of the slab depth,
    approximately parallel to the surface and approximately perpendicular to the line of the joint,
    with the centre of each bar on the intended line of the joints within a tolerance of 50 mm,
    and with a minimum cover of 30 mm below any top crack inducer or joint groove for slabs
    200 mm thick or more, or 20 mm for slabs up to 200 mm thick.
    QCS 2014 Section 06: Road Works Page 16
    Part 06: Concrete Road Pavements

    24 At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m
    long and of the same grade and size as the longitudinal reinforcement, and shall be fixed at
    twice the normal spacing midway between the longitudinal reinforcement bars so that
    750 mm 50 mm extends each side of the joint at the same level as the longitudinal
    reinforcement and be tied to the transverse reinforcement. Where paving from a construction
    joint is not resumed within 5 days, and extra longitudinal reinforcement bar at 8 m long shall
    be lapped and tied to each tie bar. These extra bars may be combined with the tie bars.
    Where the spacing between longitudinal reinforcement and the extra 8 m long bars is less
    than 90 mm, the nominal size of aggregate shall be 20 mm for a sufficient number of
    concrete batches to complete that section of pavement.

    25 Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be
    placed at the same level as the transverse reinforcement and tied to the longitudinal

    .
    reinforcement.

    l
    .l.
    rw
    Table 6.2
    Tie Bar Details

    ta
    qa
    Joints Diameter (mm) Grade of Steel Length (mm) Spacing (mm)

    Transverse Twice the


    as

    construction joints As for main spacing of


    460 1500
    in continuously reinforcement main
    se

    reinforced concrete reinforcement


    Emergency
    er

    construction joints
    in jointed reinforced
    ov

    250 or 1000 600


    concrete slabs 12
    460 deformed 750 600
    other than at
    o

    contraction or
    it

    expansion joints
    et

    250 or 1000 300


    Warping joints 12
    460 deformed 750 600
    m

    Longitudinal.
    All joints, except
    250 or 1000 600
    where transverse 12
    460 deformed 750 600
    reinforcement is
    permitted in lieu

    Note: The transverse reinforcement may be continued across the joint in reinforced concrete
    with the approval of the Engineer if the bars are of a minimum nominal diameter of
    12 mm and the bars are protected from corrosion and the cover is as required in this
    Clause.
    6.3.16 Joint Grooves

    1 Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
    QCS 2014 Section 06: Road Works Page 17
    Part 06: Concrete Road Pavements

    2 Transverse joint grooves which are initially constructed less than the full width of the slab
    shall be completed by sawing through to the edge of the slab and across longitudinal joints as
    soon as any forms have been removed and before an induced crack develops at the joint.

    3 Sawn transverse joint grooves shall be undertaken as soon as possible after the concrete
    has hardened sufficiently to enable a sharp edged groove to be produced without disrupting
    the concrete and before random cracks develop in the slab. The grooves shall be between
    1/4 and 1/3 of the specified depth of the slab and of any convenient width not less than 3mm.
    The sealing groove may be constructed at the same time to be sawn to the required width
    later. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall be
    sawn immediately before sealing.

    4 Construction Joint Grooves in Surface Slabs shall be formed by fixing a groove-former, strip
    or cork seal along the top edge of the slab already constructed, before concreting the
    adjacent slab. Where the edge of the concrete is damaged it shall be ground or made good

    l .
    to the approval of the Engineer before fixing the groove forming strip.

    .l.
    rw
    5 Alternatively the subsequent slab may be placed adjacent to the first and a sealing groove
    sawn later in the hardened concrete to the minimum depth required in Table 6.3 or to the
    manufacturer's instructions if greater, and to sufficient width to eliminate minor spalling of the

    ta
    joint arris, up to a maximum of 25mm for longitudinal joints and 40mm for transverse joints.
    qa
    The joints shall be sealed.

    6.3.17 Groove Formers and Bottom Crack Inducers


    as

    1 Except where joint grooves are sawn, a bottom crack inducer shall be provided at each
    se

    contraction, warping or longitudinal joint position.


    er

    2 The bottom crack inducer shall be an approved triangular or inverted Y-shaped fillet, with a
    base width not less than the height, made of timber or rigid synthetic material. It shall be
    ov

    firmly fixed to the sub-base so as to remain in position during the whole process of
    constructing the slab.
    o

    3 The combined depth of groove formers and bottom crack inducers shall be between 1/4 and
    it

    1/3 of the depth of the slab and the difference between the depth of the groove former and
    et

    the height of the bottom crack inducer shall not be greater than 20mm.
    m

    4 The groove former for wet formed transverse joint grooves shall be made of an approved
    rigid material of a width not greater than the required width of sealing groove as in Table 6.3.
    The groove former shall be smooth sides with rounded protrusions no greater than 3mm. Any
    removable part of the groove former may be tapered with a maximum difference in width of
    2mm in 20mm depth.

    5 Groove forming sealing strips for wet formed longitudinal joints shall be of firm compressible
    strips of ethylene vinyl acetate foam of a minimum density of 90kg/m3, or synthetic rubber, or
    equivalent material subject to approval by the Engineer. They shall have a minimum
    thickness of 5mm and shall be sufficiently rigid to remain vertical and straight in the concrete
    without curving or stretching. They shall be inserted continuously along the joint.

    6 For CRCP Universal Beam Anchorage Transverse Joints one side of the beam shall be
    separated from the CRCP slab by an expansion joint filler board against the vertical face and
    ethylene vinyl acetate foam or similar compressible material, between 5 mm and 10mm thick,
    stuck under the top flange.
    QCS 2014 Section 06: Road Works Page 18
    Part 06: Concrete Road Pavements

    6.3.18 Joint Filler Board

    1 Joint filler board for expansion joints and manhole and gully slab joint shall be 25mm
    thickness unless otherwise shown in the Drawings, within a tolerance of 1.5mm.

    2 It shall be self expanding cork seal or a firm compressible material or a bonded combination
    of compressible and rigid materials of sufficient rigidity to resist deformation during the
    passage of the concrete paving plant.

    3 The depth of the joint filler board for manhole and gully slabs shall be the full depth of the
    slab minus the depth of the sealing groove. In expansion joints, the filler board shall have a
    ridged top as shown on the Drawings, except where a sealing groove former is permitted by
    the Engineer.

    4 Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the

    l .
    sheathed dowel bar.

    .l.
    rw
    6.3.19 Preparation and Sealing of Joint Grooves

    1 All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed

    ta
    using one of the joint seals described. Additionally longitudinal joints which are sawn or
    widened shall be sealed.
    qa
    2 Joint grooves shall be prepared in accordance with BS 5212: Part 2 and in compliance with
    as

    (a) through (g) below:

    (a) that part of the groove former used to form the sealing groove or any temporary seal
    se

    shall be removed cleanly without damaging the joint arises to a minimum depth of
    25 mm where compression seals are used or otherwise to such depth as will provide
    er

    an applied seal to the dimensions as will provide in Table 6.3.


    ov

    (b) if joint grooves are not initially constructed to provide the minimum dimensions for the
    joint seals as given in Table 6.3, they shall be widened by sawing. Joint grooves
    o

    formed by tapered formers need not to be widened. The sealing grooves shall be
    it

    cleaned out immediately after sawing using high pressure water jets, to remove all
    et

    slurry from the joint, before the slurry hardens.


    (c) if rough arrises develop when grooves are made they shall be ground to provide a
    m

    chamfer approximately 5mm wide. If the groove is at an angle up to 10 degrees from


    the perpendicular to the surface, the overhanging edge of the sealing groove shall be
    sawn or ground perpendicular. If spalling occurs or the angle of the former is greater
    than 10 degrees the joint sealing groove shall be sawn wider and perpendicular to the
    surface to encompass the defects up to a maximum width, including any chamfer, of
    40 mm for transverse joints and 25mm for longitudinal joints. If the spalling cannot be
    so eliminated then the arris shall be repaired by an approved thin bonded arris repair
    using cementitious materials.
    (d) for applied sealants the sides of the joint sealing groove shall be scoured by dry
    abrasive blasting. This shall not be carried out before the characteristics compressive
    2
    strength of the concrete is expected to reach 15 N/mm . When compression seals are
    used, the sides of the groove may be ground or wire brushed.
    QCS 2014 Section 06: Road Works Page 19
    Part 06: Concrete Road Pavements

    (e) for hot and cold applied sealants, compressible caulking material, debonding strip or
    tape or cord compatible with the sealant, of a suitable size to fill the width of the sealing
    groove shall be firmly packed or stuck in the bottom of the sealing groove to such a
    depth so as to provide the correct depth of seal as described in Table 6.3 with the top
    of the seal at the correct depth below the surface of the concrete.
    (f) all grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil
    free compressed air. The groove shall be clean and dry at the time of priming and
    sealing.
    (g) for applied sealants the joint grooves shall be primed with the relevant primer for the
    hot or cold applied sealant in accordance with the manufacturer's recommendations
    and with BS 5212: Part 2, except that when necessary the joint grooves may be
    primed and sealed earlier than 14 days after construction, as soon as the grooves
    have been grit-blasted and cleaned.

    l .
    .l.
    6.3.20 Sealing with Applied Sealants

    rw
    1 Sealing shall be carried out continuously along the full length of joint in any one rip, except for
    remedial areas. When hot or cold applied sealants are used the sealant shall be applied
    within the minimum and maximum drying times of the primer recommended by the

    ta
    manufacturer. Priming and sealing with applied sealants shall not be carried out when the
    qa
    naturally occurring temperature in the joint groove to be sealed is below 10 C except
    between 8 C and 10 C it may be carried out when the temperature is rising.
    as

    2 Hot applied sealants shall be heated in and applied from a thermostatically controlled,
    indirectly heated dispenser with the recirculating pump. The sealant shall not be heated to a
    se

    temperature higher than the safe heating temperature nor for a period longer than the safe
    heating period, both as specified by the manufacturer. The dispenser shall be cleaned out at
    er

    the end of each day and reheated materials shall not be used.
    ov

    3 The components of cold-applied sealants shall be thoroughly mixed in the correct proportions
    in accordance with the manufacturer's instructions using an automatic metering and mixing
    o

    dispenser approved by the Engineer or, for hand application, using a power operated paddle
    mixer for sufficient time to produce homogenous mix without entrapped air. As soon as
    it

    possible after mixing and within the worklife of the sealant, the material shall be dispensed
    et

    into the joint, or applied using a caulking gun, to the correct level below the concrete surface.
    m

    The tack-free time shall be achieved within 3 hours, for machine dispensed material, or within
    12 hours for hand applied material.

    4 Test certificates shall be supplied from an approved testing laboratory stating that the sealant
    complies with the relevant standard. Site testing of cold applied sealants shall be in
    accordance with BS 5212: Part 2. Hot-applied sealants shall be sampled at the same rate
    and checked for dimensions as in BS 5212: Part 2 and by the penetration test of the relevant
    standard for the material.
    QCS 2014 Section 06: Road Works Page 20
    Part 06: Concrete Road Pavements

    Table 6.3
    Dimensions of Applied Joint Seals

    Type and Minimum Cold Hot Impregnated Depth of Seal


    Spacing of Width (mm) Applied Applied Foam Below the
    Joints (m) (mm) (mm) Compression Concrete
    Strips (mm) Surface(mm)
    Contraction:
    15 and under 13 (Note 2) 13 15 30 5+2
    Over 15 to 20 20 15 20 30 5+2
    Over 20 to 25 30 20 25 40 5+2
    Expansion All 30 20 25 40 7+2
    Transverse 10 10 13 30 5+2
    Warping

    .
    Longitudinal 10 10 13 30 0 to 5

    l
    .l.
    Joints (if
    sealed)

    rw
    Gully and 20 15 20 30 0 to 3
    Manhole Slabs

    Note: (1) ta
    The depth of seal is that part in contact with the vertical face of the joint groove.
    qa
    The depth of seal below the surface shall be taken at the centre of an applied
    seal relative to a short straight edge, 150mm long, placed centrally across the
    joint within 7 days of sealing.
    as

    Note: (2) For cork seals other than in construction joints, grooves shall be 20 mm wide and
    se

    50 mm deep.
    6.3.21 Sealing with Compression Seals
    er

    1 When compression seals are used, the widths of the seal shall be selected in relation to the
    ov

    width of the sealing groove, the bay lengths and manufacturer's recommendations so that the
    estimated maximum width of the joint opening shall be not more than 70% of the original
    o

    width of the seal, the estimated maximum width being calculated on the basis of a movement
    it

    of 4mm per 10m run of slab.


    et

    2 The maximum calculated width of sealing groove shall be 30mm.


    m

    3 The depth of groove shall be such that the contact face of the seal with the side of the groove
    shall be not less than 20mm and that the top of the seal shall be a minimum of 3mm below
    the surface of the concrete.

    4 Compression seals shall be inserted into the grooves without prior extension or rotation and,
    where recommended by the manufacturer, with a lubricant adhesive which is compatible with
    the seal and the concrete. The adhesive shall be applied to both sides of the sealing groove
    or the seal, or to both. The seal shall be positioned with its axis perpendicular to the concrete
    surface. Excess adhesive on top of the seal shall be removed to prevent adhesion of the top
    faces of the seal under compression.

    5 Except when compression seals are used in longitudinal joints the transverse joint seal shall
    be continuous across the slab and the longitudinal joint groove forming strips shall be cut to
    the required depth after the concrete has hardened for the transverse seal to be inserted.
    QCS 2014 Section 06: Road Works Page 21
    Part 06: Concrete Road Pavements

    6 If compression seals are used in longitudinal joints where the grooves have been sawn after
    construction of the slab they shall be continuous across transverse joints, with the transverse
    seals butted and fixed to the longitudinal seals with adhesive.

    6.3.22 Joint Seals

    1 Joint seals shall consist of hot or cold applied sealants or compression seals or self
    expanding cork seals.

    2 Hot-applied sealants shall comply with ASTM Standard D3406, or D7116 (for fuel-resistant
    sealant).

    3 For joints between concrete surface slabs and bituminous surfacing, polymer modified
    bitumen sealing strips shall be used and applied in accordance with the manufacturer's
    instructions. Hot-applied sealants complying with BS 2499 & BS EN 14188 may be used for

    l .
    such joints and in joints in asphalt kerbs laid on concrete pavements.

    .l.
    rw
    4 Cold applied sealants shall be Type N complying with BS 5212: Part 1 except that Type F
    shall be used for lay-bys and hardstandings.

    5
    ta
    For joints in kerbs and joints other than in pavements, seals may be any of the pavement
    sealants if they have the suitable characteristics for the application. Also, gunning grade cold
    qa
    applied plasticised bituminous rubber sealant or gunning grades of two part polysulphid-
    based sealants complying with BS EN ISO 11600 may be used.
    as

    6 Alternatively, polyurethane-based sealing compounds may be used provided their


    se

    performance is not inferior to BS EN ISO 11600 material.

    7 Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing


    er

    strip, or rubber seals made of polychloroprene elastomers complying with BS 2752 and
    ov

    conforming to the requirements of ASTM Standard D2628-91.

    8 Compression seals shall be shaped so that they will remain compressed at all times and
    o

    shall have a minimum of 20mm contact face with the sides of the sealing groove. If lubricant
    it

    adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant
    et

    to abrasion, oxidisation, fuels and salt.


    m

    9 Self Expanding Cork seals may be used in longitudinal joints, joints for manhole and gully
    slabs and for transverse joints in short lengths of individual slabs or for replaced slabs.

    6.3.23 Joints at Manhole and Gully Slabs

    1 Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be
    contained in separate small slabs, which shall be larger than the exterior of the manhole and
    gully shafts, including any concrete surround less than 150mm below the underside of the
    sub-base layer. The joint around the manhole or gully slab shall be vertical and incorporate
    joint filler board but without dowel bars and tie bars.

    2 Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint,
    extending the gully slab as necessary to a maximum of 2m. Where this is impractical, an
    extra tied warping joint shall be provided adjacent to or within the gully slab and at least 2m
    from the next transverse joint. If the edge of an isolator slab is within 1m of any longitudinal
    joint the isolator slab shall be extended to that joint.
    QCS 2014 Section 06: Road Works Page 22
    Part 06: Concrete Road Pavements

    3 Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or


    longitudinal joints. If the manhole is within the middle third of the bay length a warping joint
    shall be constructed on one side of the manhole slab across the whole width of the bay to the
    nearest longitudinal joint.

    4 Reinforcement as shown on the Drawings shall be placed in the main concrete slabs in the
    corners between the manhole and gully slab and the transverse or longitudinal joints. Extra
    reinforcement as described in the Contract shall be placed in reinforced concrete slabs
    around the manhole or gully slabs.

    5 Manhole and gully slabs shall have oblique corners, minimum 200mm long, at approximately
    45 degrees to the axis of the pavement at all corners which are not adjacent to a transverse
    or longitudinal joint in the main slab.

    6 Reinforcement as shown on the Drawings shall be placed in the gully or manhole slab and

    l .
    concrete grade C40 shall be placed by hand in the space between the main slab and the

    .l.
    manhole frame. The concrete shall be fully compacted and finished.

    rw
    7 A sealing groove shall be made directly above the joint filler board and sealed.

    6.3.24 Inspection of Dowel Bars


    ta
    qa
    1 The position and alignment of dowel bars at contraction and expansion joints shall be
    checked by measurement relative to the side form or guide wires.
    as

    2 When the slab has been constructed, the position and alignment of dowel bars and any filler
    se

    board shall be measured after carefully exposing them across the whole width of the slab.
    When the joint is an expansion joint the top of the filler board shall first be exposed
    er

    sufficiently in the plastic concrete to permit measurement of any lateral or vertical


    displacement of the board. During the course of normal working these measurements shall
    ov

    be carried out at a rate of one joint per 1500m length of slab or one per 5 working days
    whichever occurs the sooner. For small areas the rate shall be decided by the Engineer.
    o

    3 If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the
    it

    next two joints shall be inspected. If only one joint of the three is defective, the rate of
    et

    checking shall be increased to one joint per day until the Engineer is satisfied that
    compliance is being achieved. In the event of non-compliance in two or more successive
    m

    joints, the Contractor shall revert to the construction of trial lengths and make any necessary
    alterations to the concrete mix, paving plant or methods until the dowel bar position and
    alignment is satisfactory.

    4 After the dowel bars have been examined, the remainder of the concrete shall be removed
    500mm on each side of the line of the joint, and reinstated to the satisfaction of the Engineer.
    Alternatively if the dowels are examined in the penultimate joint of a day's work that joint shall
    be made a construction joint for the next day's work and the remainder of the concrete in the
    last slab may be discarded.

    6.3.25 Side Forms, Rails and Guide Wires

    1 All side forms and rails shall be made of steel and be sufficiently robust and rigid to support
    the weight and pressure caused by the paving equipment. Side forms for use with wheeled
    paving machines shall incorporate metal rails firmly fixed at a constant height below the top
    of the forms.
    QCS 2014 Section 06: Road Works Page 23
    Part 06: Concrete Road Pavements

    2 The forms shall be secured by using not less than three pins for each 3m length having one
    pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint,
    free from play or movement in any direction. Forms shall be cleaned and oiled immediately
    before each use. The rails or running surface shall be kept clean in front of the wheels of any
    paving machine. The forms shall be straight within a tolerance of 3mm in 3m.

    3 The forms shall be bedded on low moisture content cement mortar or concrete grade C7.5
    and set to the pavement surface level as shown on the Drawings within a tolerance of +3mm.
    The bedding shall not extend under the slab. There shall be no vertical step between the end
    of adjacent forms greater than 3mm. The horizontal alignment for forms shall be to the
    required alignment of the pavement edge as shown on the Drawings within a tolerance of +
    10mm. The mortar or concrete bedding shall be broken out after use.

    4 Side forms shall not be removed earlier than 6 hours after the completion of the construction
    of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie

    l .
    bars during the removal of the forms. If the removal of forms results in any damage to the

    .l.
    concrete the period of 6 hours shall be increased to that which is necessary to avoid further

    rw
    damage and the Contractor shall make good the damaged areas.

    5 Unless otherwise agreed by the Engineer, a guide wire shall be provided along each side of

    ta
    the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant
    qa
    height above and parallel to the required edges of the slab as shown on the Drawings, within
    a vertical tolerance of + 3mm. Additionally one of the wires shall be at a constant horizontal
    distance from the required edge of the pavement as shown in the drawings within a lateral
    as

    tolerance of + 10mm.
    se

    6.3.26 Delivery, Storage and Batching of Concreting Materials


    er

    1 Aggregate for roadworks shall be delivered to and stored on the Site in one of the following
    ways:
    ov

    (a) in separate nominal single sizes of coarse aggregate and fine aggregate.
    (b) as graded coarse aggregate of appropriate size and fine aggregate.
    it o

    (c) as all-in aggregate for grades C20 to below.


    et

    2 If the Contractor proposes to blend aggregate off the site from two separate sources, he shall
    m

    obtain the Engineer's approval for the blending process, and for the arrangements for
    inspection during the course of the work.

    3 Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Fine
    aggregate nominally below 5 mm sieve size shall have been deposited at the site for at least
    8 hours before use.

    4 Batching plant and storage for aggregate shall comply with the following requirements as
    appropriate to the method of delivery:

    (a) if separate gradings of aggregate are stockpiled, separate accommodation shall


    be provided for each nominal size of coarse aggregate or blend of fine
    aggregate. The base for stockpiles shall be suitably surfaced to prevent
    contamination of the aggregate. Drainage of the stockpile bases shall be
    provided.
    QCS 2014 Section 06: Road Works Page 24
    Part 06: Concrete Road Pavements

    (b) aggregate shall be measured by mass and provision shall be made for batching
    each nominal size or blend of aggregate separately, to the tolerances specified in
    BS EN 206 & BS 8500.
    (c) all-in aggregate shall be delivered and stockpiled in such a manner and to a
    height that avoids segregation.

    6.3.27 Mixing Concrete

    1 Mixing concrete shall conform to the requirements of Section 5 Part 7 except as amended
    herein.

    2 Concrete shall be mixed on site in a stationary batch type mixer in compliance with BS EN
    206 & BS 8500 unless with the approval of the Engineer, ready mixed concrete is supplied
    from an approved source.

    l .
    .l.
    3 The drums or blades of all mixers shall be operated at the speed using for testing, in
    accordance with BS 3963 for the mix proportions required, within a tolerance of 1 revolution

    rw
    per minute. The mixing blades of a pan mixer shall be maintained within the tolerances
    specified by the manufacturers of the mixer and the blades shall be replaced when it is no
    longer possible to maintain the tolerances by adjustment. All drums or pans which have
    ta
    been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh
    qa
    concrete is mixed in them.

    4 The rated output of the batching and mixing plant shall exceed by at least a third the amount
    as

    of concrete that is required at a constant rate to enable the paving train to move forward
    continuously, at the planned rate of progress.
    se

    6.3.28 Transport and Delivery


    er

    1 Transportation, delivery of concrete shall conform to the requirements of Section 5 Part 8.


    ov

    6.3.29 General Requirements for Construction by Machine


    o

    1 The concrete slab shall be constructed in a continuous process by either slip-form or by fixed
    it

    form paving plant or by small paving machines or hand guided methods.


    et
    m

    2 The slab may be constructed in either one or two layers. In two layer construction the
    thickness of the top layer shall be not less than 50mm or twice the maximum size of the
    coarse aggregate whichever is greater, and shall be at least 15 mm thick than the depth of
    the groove former, if used.

    3 While the concrete is still plastic its surface shall be brush-textured and the surface and
    edges shall be cured.

    4 The spreading, compacting and finishing of the concrete shall be carried out as rapidly as
    possible and the paving operation shall be so arranged as to ensure that the time between
    the mixing of the first batch of concrete in any transverse section of the slab and the
    application of the sprayed curing membrane to the surface of that section shall not exceed
    those given in Table 6.4.

    5 Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge
    next to a transverse joint while the concrete is plastic. In continuously reinforced concrete
    pavement the slab shall be marked with the chainage at intervals not greater than 50m apart.
    QCS 2014 Section 06: Road Works Page 25
    Part 06: Concrete Road Pavements

    6.3.30 Construction by Fixed Form Paving Machines

    1 A fixed form paving train shall consist of separate, powered machines which spread compact
    and finish the concrete in a continuous operation.

    2 Concrete shall be discharged without segregation into a hopper spreader which is equipped
    with the means of controlling its rate of deposition onto the sub-base or onto the lower layer.
    The concrete shall be spread in each layer without segregation and to a uniform
    uncompacted density over the whole area of the slab.

    3 The deposited concrete shall be struck off to the necessary level by the underside of the
    hopper as it is traversed across the spreading machine.

    4 The machine shall be capable of being rapidly adjusted for changes in average and
    differential surcharge necessitated by changes in slab thickness or crossfall. When the slab

    l .
    is constructed in two layers, the spreading of the concrete in the top layer shall follow the

    .l.
    completion of the bottom layer within the times given in Table 6.4.

    rw
    5 Prior to being compacted, the surface level of each loose spread layer shall be adjusted to
    the correct surcharge by means of rotating strike-off blades or a screw device.

    6 ta
    The concrete shall be compacted by vibration or by a combination of vibration and
    qa
    mechanical tamping throughout the full depth of the slab. Poker vibrators shall be used in
    each layer adjacent to the side forms and the edge of a previously constructed slab.
    as

    7 The initial regulation and finish to the surface of the slab shall be effected by means of a
    se

    beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam
    shall be readily adjustable for both height and tilt.
    er

    8 When grooves are wet-formed the concrete shall be recompacted around the former by a
    ov

    hand held vibrating plate compactor drawn along or on each side of the joint, prior to
    regulation of the surface by the diagonal finishing beam. Or recompacted and finished if the
    former is inserted after the finishing beam.
    it o

    9 The regulation and finishing of the surface of the slab shall be carried out by a machine which
    et

    incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both
    height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and
    m

    span the full width of the slab. The leading beam shall be vibrated. The beams shall be
    supported on a carriage, the level of which shall be controlled by the average level of not less
    than four points evenly spaced over at least 3.5m of the supporting rail, beam or slab, on
    each side of the slab that is being constructed. After the final regulation and before texture is
    applied any excess concrete on top of the groove former shall be removed.

    10 When a concrete slab is constructed in more than one width, flanged wheels on the paving
    machines shall not be run directly on the surface of any completed part of the slab. The
    second or subsequent slabs shall be constructed either by supporting machines with flanged
    wheels on flat bottom section rails weighing not less than 15 kg/m laid on the surface of the
    completed slab, or by replacing the flanged wheels on that side of the machines by smooth
    flangeless wheel.. Flangeless wheels or rails shall be positioned sufficiently far from the
    edge of the slab to avoid damage to that edge.
    QCS 2014 Section 06: Road Works Page 26
    Part 06: Concrete Road Pavements

    6.3.31 Construction by Slip-Form Paving Machine

    1 A slip-form paving train shall consist of powered machines which spread, compact and finish
    the concrete in a continuous operation.

    2 The slip-form paving machine shall compact the concrete by internal vibration and shape it
    between sliding side forms or over fixed side forms by means of either a conforming plate or
    by vibrating and oscillating finishing beams.

    3 The concrete shall be deposited without segregation in front of the slip-form paver across its
    whole width and to a height which at all times is in excess of the required surcharge. The
    deposited concrete shall be struck off to the necessary average and differential surcharge by
    means of a strike-off plate or a screw auger device extending across the whole width of the
    slab. The equipment for striking off the concrete shall be capable of being rapidly adjusted
    for changes of the average and differential surcharge necessitated by changes in slab

    l .
    thickness or crossfall.

    .l.
    rw
    4 The level of the conforming plate and finishing beams shall be controlled automatically from
    the guide wires by sensors attached at the four corners of the slip form paving machine. The
    alignment of the paver shall be controlled automatically from the guide wire by at least one

    ta
    sensor attached to the paver. The alignment and level of ancillary machines for finishing,
    qa
    texturing and curing of the concrete shall be automatically controlled relative to the guide wire
    or to the surface and edge of the slab.
    as

    5 Slip-form paving machines shall have a vibration of variable output, with a maximum energy
    output of not less than 2.5 kW per metre width of slab per 300mm depth of slab for a laying
    se

    speed of up to 1.5m per minute or pro rata for higher speeds. The machines shall be of
    sufficient mass to provide adequate reaction on the traction units to maintain forward
    er

    movements during the placing of concrete in all situations.


    ov

    6 Where grooves are wet-formed the concrete shall be compacted around the former by a
    separate vibrating plate compactor with twin plates. The groove former shall be compacted to
    the correct level by a vibrating pan which may be included with the transverse joint finishing
    o

    beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the
    it

    surface along the joint. Alternatively the surface shall be regulated with a longitudinal
    et

    oscillating float travelling across the slab. Any excess concrete on top of the groove former
    m

    shall be removed before the surface is textured.

    7 Where a concrete surface slab is constructed in more than one width or where the edge
    needs to be matched for level to another section of surface slab, and the surface levels at the
    edges are not achieved, paving shall be carried out over separate fixed side forms to support
    the edge to the required levels.

    6.3.32 Construction by Small Paving Machines or Hand Guided Methods

    1 As an alternative to fixed form or slip-form paving trains, the concrete slab may be
    constructed using parts of trains, small paving machines, truss type finishing beams or hand
    guided methods. Hand tamping beams may only be used for short lengths or infill bays or
    tapers. Reinforcement, dowel bars and tie bars shall be supported in position, except where
    two layer construction is used and reinforcement is placed on the bottom layer in a method of
    construction approved by the Engineer.
    QCS 2014 Section 06: Road Works Page 27
    Part 06: Concrete Road Pavements

    2 The concrete shall be spread uniformly without segregation or varying degrees of


    precompaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a
    screed or auger so that the average and differential surcharge is sufficient for the surface of
    the slab to be at the correct levels after compaction of the concrete.

    3 The concrete shall be compacted by vibrating finishing beams across the slab and with
    vibrating pokers adjacent to the side forms or the edge of a previously constructed slab. In
    addition, internal poker vibration shall be used for slabs thicker than 200mm and may be
    used for lesser thicknesses. When used, the pokers shall be at points not more than 500mm
    apart over the whole area of the slab, or drawn continuously across the slab in front of the
    finishing beams.

    4 The finishing beams shall be metal with a contact face at least 50mm wide. They shall be
    rigid or supported by a frame or truss without sag across the width of slab being paved. The
    beams shall be supported on rails or forms or an adjacent slab and shall be moved forward

    l .
    at a steady speed of 0.5m to 2m per minute whilst vibrating, to compact the concrete and to

    .l.
    produce a smooth surface finished to the correct crossfalls, crowns and levels relative to the

    rw
    top of the forms or adjacent slab.

    5 Any irregularities at wet-formed joint grooves shall be rectified by means of a vibrating float at

    ta
    least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be
    qa
    regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further
    application of a twin vibrating finishing beam. All slabs shall be checked for level using a
    straight edge at least 4m long. Any excess concrete on top of the groove former shall be
    as

    removed before the surface is textured.


    se

    6 The surface shall be brush textured.


    er

    7 The surface shall be cured within the time to completion given in Table 6.4
    ov

    Table 6.4
    Maximum Working Times
    it o

    Reinforced Concrete Slabs


    et

    All other Concrete Slabs


    Temperature of Consumed in Two layers
    m

    concrete at discharge
    Mixing first Mixing first
    from the delivery between
    layer to between layer to
    vehicle layers in 2
    finishing layers finishing
    layer work
    concrete concrete

    Not more than 25 C 3 hours 1/2 hour 3 hours 1 1/2 hours

    Exceeding 25 C 2 hours 1/2 hour 2 hours 1 hour

    unacceptable
    unacceptable
    Exceeding 30 C for paving
    for paving
    QCS 2014 Section 06: Road Works Page 28
    Part 06: Concrete Road Pavements

    6.3.33 Surface Textures

    1 After the final regulation of the surface of the slab and before the application of the curing
    membrane, the surface of concrete slabs to be used as running surfaces shall be brush
    textured in a direction at right angles to the longitudinal axis of the carriageway.

    2 The texture shall be applied evenly across the slab in one direction by a brush not less than
    450 mm wide. The texture shall be uniform both along and across the slab.

    3 Curing

    4 Immediately after the surface treatment, the surface and exposed edges of surface slabs
    shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter
    period). This will be by the application of an approved resin based aluminised curing

    .
    compound, or polythene sheeting or an approved sprayed plastic film which hardens into a

    l
    .l.
    peelable plastic sheet. It shall be removed before road marking and opening to traffic.

    rw
    5 Resin based aluminised curing compound shall contain sufficient flake aluminium in finely
    divided dispersion to produce a complete coverage of the sprayed surface with a metallic
    finish. The compound shall become stable and impervious to evaporation of water from the
    ta
    concrete surface within 560 minutes of application and shall have an efficiency index of 90%
    qa
    when tested as described in BS 7542.

    6 The curing compound shall not react chemically with the concrete to be cured and shall not
    as

    crack, peel or disintegrate within three weeks after application.


    se

    7 Prior to application, the contents of any containers shall be thoroughly agitated. The curing
    compound shall be mechanically applied using a fine spray onto the surface at a rate of at
    er

    least 0.221L/m2. For the sides of slip-formed slabs or when the side forms are removed
    within 24 hours and for small areas where mechanical application cannot be used, the
    ov

    compound shall be sprayed by hand lance at a rate of at least 0.271/m2. The rate of spread
    shall be checked during construction of each trial length and subsequently whenever required
    by the Engineer.
    it o

    8 The mechanical sprayer shall incorporate an efficient mechanical device for continuous
    et

    agitation and mixing of the compound in its container during spraying.


    m

    9 Continuously reinforced concrete road bases shall also be cured. Wet lean concrete road
    bases and sub-bases shall also be cured.

    10 REQUIREMENTS FOR WET LEAN CONCRETE

    11 Materials and Mix Designs

    12 The constituent materials and the grades of concrete for wet lean mix shall comply with the
    requirements of Section 5: Part 16.

    13 Placing

    14 Wet lean concrete shall be spread uniformly without segregation and without varying degrees
    of pre-compaction.
    QCS 2014 Section 06: Road Works Page 29
    Part 06: Concrete Road Pavements

    15 The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that
    after compaction the surface is at the required level.

    16 Compaction

    17 The spread wet lean concrete shall be compacted using internal or external vibration, or
    combination of both to meet the required density.

    18 Compaction and finishing to level shall be completed within the times given in Table 6.4.

    19 Joints

    20 At transverse and longitudinal construction joints between two separately constructed slabs,
    the previously laid slab end or edge shall present a vertical face before construction of
    subsequent slabs.

    l .
    .l.
    21 Longitudinal joints in wet lean concrete shall be staggered by at least 300mm from the

    rw
    position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse
    joints.

    6.3.34 Strength
    ta
    qa
    1 From each sample, three cubes of the appropriate size shall be made, cured and tested in
    compliance with BS 1881.
    as

    2 One of each group shall be tested at 7 days and the other two at 28 days. The cubes shall
    be assessed for compliance on groups of four 28-day test results in accordance with BS EN
    se

    206 & BS 8500 for compliance with the grade required.


    er

    3 If the average value of any four consecutive results of tests at 7 days falls below the required
    ov

    values the cement content of the mix shall be increased by an amount agreed with the
    Engineer which shall be maintained until the corresponding 28-day test results have been
    assessed.
    it o

    6.3.35 Trial Mixes


    et

    1 Trial mixes complying with the requirements for pavement quality concrete shall be required
    m

    for designed mixes for Grade C15 and above, unless recent data relating to the proposed
    mix is approved by the Engineer.

    6.3.36 Trial Length

    1 At least 10 days before the start of the main wet lean concrete works a trial length of at least
    400 m2 for mechanised construction and 30m for hand guided methods shall be constructed.

    2 The trial length shall be laid to assess the suitability of the proposed material, plant,
    equipment and construction methods to meet the requirements of the Specification.

    3 The main construction in the permanent works shall not start until the trial length has been
    approved by the Engineer.
    QCS 2014 Section 06: Road Works Page 30
    Part 06: Concrete Road Pavements

    4 If any trial length does not conform to the Specification another trial length shall be
    constructed. Trial lengths not complying with the Specification shall be removed unless they
    can be rectified to comply with the Specification to the satisfaction of the Engineer.

    5 After approval has been given, the material plant, equipment and construction methods shall
    not be changed without the approval of the Engineer.

    6 Any proposed changes shall entitle the Engineer to require the Contractor to lay a further trial
    length to assess the suitability of the proposed changes.

    6.3.37 Surface Finish

    1 The surface of the wet lean concrete after compaction and finishing and before overlaying
    shall be free from ridges, loose material, pot holes, ruts or other defects.

    l .
    2 The surface texture shall comply with the sub-Clause for pavement quality concrete, Section

    .l.
    5: Part 16.

    rw
    6.4 REQUIREMENTS FOR CEMENT BOUND MATERIALS

    6.4.1 General Requirements for Cement Bound Materials


    ta
    qa
    1 Cement bound materials shall be made and constructed as described in the following
    clauses.
    as

    2 Cement bound materials shall be tested in accordance with this specification for the
    se

    requirements of Table 6.5


    er

    3 Cement water and aggregates shall comply with the requirements of the Section 5: Part 16.
    ov

    4 Cement for use in all cement bound materials and aggregates for use in CBM3 and CBM4
    shall be delivered and stored in compliance with the requirements of Section 5: Part 16.
    o

    Table 6.5
    it

    Cement Bound Materials Field Requirements


    et
    m

    Method of Moisture Minimum


    Category Mixing Plant
    Batching Content Compaction

    mix in place or
    CBM 1 volume or mass NOTE 1 NOTE 2
    mix in the plant
    mix in place or
    CBM 2 volume or mass NOTE 1 NOTE 2
    mix in the plant

    CBM 3 mix in the plant mass NOTE 1 NOTE 2

    mix in place or
    CBM 4 volume or mass NOTE 1 NOTE 2
    mix in the plant

    NOTE 1 to suit the requirements for strength surface, level regularity and finish
    NOTE 2 95% of cube strength
    QCS 2014 Section 06: Road Works Page 31
    Part 06: Concrete Road Pavements

    Table 6.6
    Cement Bound Materials Specimen Requirements

    Minimum 7 days Cube


    Strength
    Compressive Strength
    Category Curing
    Testing Average Individual
    (Note1) (Note2)
    (MPa) (MPa)

    BS 1924 Part 2 1990


    CBM 1 BS 1924 Part 2 1990 4.5 2.5
    or BS 1881Part 116

    BS 1924 Part 2 1990


    CBM 2 BS 1924 Part 2 1990 7.0 4.5
    or BS 1881 Part 116

    l .
    .l.
    CBM 3 BS 1881 Part 111 BS 1881 Part 116 10.0 6.5

    rw
    CBM 4
    ta
    BS 1881 Part 116 15.0 10.0
    qa
    NOTE 1 The average strength of 5 cubes shall not be less than the stated figure
    as

    NOTE 2 The strength of any individual cube shall not be less than the stated figure
    6.4.2 Batching and Mixing
    se

    1 Batching and mixing shall be carried out in the appropriate manner described in Table 6.5.
    er

    2 Where the mix-in plant method is used and materials are batched by mass, the materials
    ov

    shall be batched and mixed in compliance with BS EN 206 & BS 8500. Where continuous
    mixers are used and materials are batched by mass, the continuous mixers shall comply and
    tested in accordance with BS 3963.
    it o

    6.4.3 Transporting
    et
    m

    1 Plant-mixed cement bound material shall when mixed be removed at once from the mixer,
    transported directly to the point where it is to be laid and protected from the weather both
    during transit from the mixer to the laying site and whilst awaiting tipping.

    6.4.4 Laying

    1 All cement bound material shall be placed and spread evenly in such manner as to prevent
    segregation and drying.

    2 Spreading shall be undertaken either concurrently with placing or without delay.

    3 Road base cement bound material shall be spread using a paving machine or a spreader box
    approved by the Engineer and operated with a mechanism which levels off the cement bound
    material to an even depth.

    4 Cement bound material shall be spread in one layer so that after compaction the total
    thickness is as specified.
    QCS 2014 Section 06: Road Works Page 32
    Part 06: Concrete Road Pavements

    5 At longitudinal or transverse construction joints, unless vertical forms are used, the edge of
    compacted cement bound material shall be cut back to a vertical face where the correct
    thickness of properly compacted cement bound material has been obtained.

    6 In the case of cement bound sub bases under a concrete surface slab or continuously
    reinforced concrete road base, longitudinal construction joints in the sub-base shall be
    staggered by at least 300mm from the position of the longitudinal joints in the concrete
    surface slab or continuously reinforced concrete road base, and by 1m for transverse joints.

    6.4.5 Compacting

    1 Compaction shall be carried out immediately after the cement bound material has been
    spread and in such a manner as to prevent segregation.

    2 Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and

    l .
    transverse construction joints.

    .l.
    rw
    3 Compaction shall be carried out in compliance with Table 6.5 and be completed within
    2 hours of the addition of the cement. The 2 hours may be varied at the discretion of the
    Engineer if the preliminary trial indicates that this is necessary or appropriate. After
    ta
    compaction has been completed, compacting equipment shall not bear on cement bound
    qa
    material for the duration of the curing period.

    4 The surface of any layer of cement bound material shall on completion of compaction and
    as

    immediately before overlaying, be well closed, free from movement under compaction plant
    and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated
    se

    or otherwise defective areas shall be removed to the full thickness of the layer and new
    cement bound material laid and compacted.
    er

    6.4.6 Curing
    ov

    1 Immediately on completion of compaction, the surface of concrete or wet lean concrete or


    cement bound road bases and sub-bases shall be cured for a minimum period of 7 days
    o

    (unless the Engineer agrees to a shorter period) by one of the following methods:
    it
    et

    2 Covering with an impermeable sheeting with joints overlapping at least 300 mm and set to
    m

    prohibit egress of moisture. The sheeting shall be removed at the end of the curing period.

    3 Bituminous spraying which shall only be applied when there is no visible water. When the
    cement bound material is likely to be exposed to high temperatures and solar radiation, the
    bituminous spray shall be blinded with light coloured material.

    4 Spraying with a curing compound.

    5 Spraying with an approved plastic film which when hardened shall be removed before
    applying any other pavement layer.

    6 Whichever method is used, immediately prior to overlaying with any bituminous layer in
    cationic bituminous tack coat shall be applied at a rate between 0.351/m2 to 0.551/m2.
    QCS 2014 Section 06: Road Works Page 33
    Part 06: Concrete Road Pavements

    6.4.7 Preliminary Trial

    1 At least 10 days before the start of the main cement bound material works a trial area of at
    least 400 m2 shall be laid to asses the suitability of the proposed materials, mix proportions,
    mixing, laying, compaction plant and construction procedures.

    2 When applicable the area shall include one longitudinal and one transverse construction joint.
    The location and area of the trial shall be subject to the approval of the Engineer.

    3 The rate of testing for the trial area shall not be less than that required in this section of the
    specification.

    4 The trial area will only be accepted for main construction in the Permanent Works if it
    complies with the Specification.

    l .
    .l.
    5 The main construction in the Permanent Works shall not start until the trial has been
    approved by the Engineer.

    rw
    6 After approval has been given, the materials, mix proportions, mixing, laying compaction
    plant and construction procedures shall not be changed without the approval of the Engineer

    ta
    who may require the Contractor to lay a further trial area to assess the suitability of the
    qa
    proposed changes.

    6.4.8 Cement Bound Material Category 1 (CBM1)


    as

    1 CBM1 shall be made from material which has a grading finer than the limits of Table 6.7
    se

    2 In addition to the requirements of Table 6.6 the average compressive strength determined
    er

    after immersion in water of five test specimens of CBM1 shall not be less than 80% of the
    average compressive strength of five control specimens when subjected to the test
    ov

    procedure described in BS 1924: Part 2: 1990, clause 4.3.

    3 After the 7 days immersion period the specimens shall not show any signs of cracking or
    o

    swelling.
    it
    et

    Table 6.7
    Material for CBM1 - Limit of Grading
    m

    BS Sieve Size (mm) Percentage by Mass Passing

    50 100
    37.5 95
    20 45
    10 35
    5 25
    0.600 8
    0.300 5
    0.075 0

    NOTE: The particle size distribution shall be determined by the washing and sieving
    method of BS812:
    QCS 2014 Section 06: Road Works Page 34
    Part 06: Concrete Road Pavements

    6.4.9 Cement Bound Material Category 2 (CBM2)

    1 CMB2 shall be made from gravel sand, a washed or processed granular material, crushed
    rock, all in aggregate, blastfurnace slag or any combination of these. The material shall fall
    within the grading limits of Table 6.8.

    2 The material shall have 10 % fines value of 50 kN or more when tested in accordance with
    BS 812 with samples in a soaked condition.

    3 In addition to the requirements of Table 6.6 the average compressive strength determined
    after immersion in water of five test specimens of CBM2 shall not be less than 80% of the
    average compressive strength of five control specimens when subjected to the test
    procedure described in BS 1924: Part 2: 1990, clause 4.3. After the 7 days immersion period
    the specimen shall not show any signs of cracking or swelling.

    l .
    .l.
    Table 6.8
    Material For CBM2 - Range Of Grading

    rw
    BS Sieve Size
    ta
    Percentage by Mass Passing
    qa
    50 100
    37.5 95-100
    as

    20 45-100
    10 35-100
    se

    5 25-100
    er

    2.36 15-90
    0.600 8-65
    ov

    0.300 5-40
    0.075 0-10
    it o

    NOTE: The particle size distribution shall be determined by the washing and sieving
    et

    method of BS 812.
    m

    6.4.10 Cement Bound Material Category 3 (CBM3)

    1 CBM3 shall be made from aggregates as in the sub-Clause 6.5.9.

    2 The grading of the aggregate shall be within the limits of Table 6.9.

    6.4.11 Cement Bound Material Category 4 (CBM4)

    1 CBM4 shall be made from aggregates as in sub-Clause 6.5.9

    2 The grading of the aggregate shall be within the limits of Table 6.9.
    QCS 2014 Section 06: Road Works Page 35
    Part 06: Concrete Road Pavements

    Table 6.9
    Material for CBM3 and CBM4 - Range of Grading

    Percentage by Mass Passing.


    BS Sieve Size (mm)
    Nominal Maximum Size

    40 mm 20 mm
    50 100 -
    37.5 95-100 100
    20 45-80 95-100
    5 25-5- 35-55
    0.600 8-30 10-35
    0.150 0.8* 0-8*

    .
    0.075 0.5 0-5

    l
    .l.
    rw
    NOTE: The particle size distribution shall be determined by the washing and sieving
    method of BS 812.
    *0-10 for crushed rock fines
    6.4.12 Testing of Cement Bound Materials ta
    qa
    1 Samples shall be provided in accordance with BS 1924: Part 1: 1990 Clause 5 from the laid
    cement bound material before compaction. One group of five samples shall be provided from
    as

    five locations equally spaced along a diagonal that bisects each 800 mm2 or part thereof laid
    each day. The number of groups may be increased if required by the Engineer.
    se

    2 One 150 mm cube shall be made from each sample taken in accordance with sub-clause 1
    er

    of this clause. The cubes shall be made in accordance with BS 1924: Part 2: 1990, clause
    4.2.5 without further mixing of the material and within 2 hours of the addition of the cement.
    ov

    Cubes shall be cured and tested in accordance with Table 6.6.


    o

    3 To determine the wet density of cubes the mould shall be weighed prior to making the cube
    it

    and the mass recorded. Immediately after completion of compaction, the cube and mould
    et

    shall be weighed and the mass recorded. These masses together with the nominal volume of
    the mould shall be used to derive the wet density of the cube.
    m

    4 The in-situ wet density of a layer of cement bound material shall be taken as the average of
    the wet densities at five locations equally spaced along a diagonal that bisects each 800 m2
    or part thereof laid each day. The wet density at each location shall be the average of two
    readings obtained using a nuclear density gauge complying with BS 1377: Part 9. The two
    readings shall be taken at 180 degrees to each other using the same source rod hole. The
    source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings
    shall be taken within two hours of completing final compaction.

    6.4.13 Special Requirements for Cement Bound Materials

    1 Where specified in the contract documents or on the project drawings cement bound road
    base in flexible composite construction shall be laid in individual widths with longitudinal
    construction joints in locations as detailed below:

    (a) Single All purpose. One longitudinal construction joint at the centre lane line marking.
    QCS 2014 Section 06: Road Works Page 36
    Part 06: Concrete Road Pavements

    (b) Dual 2 lane All-purpose. One longitudinal construction joint at the lane line marking.
    (c) Dual 3 lane All-purpose. Two longitudinal construction joints, one at each of the lane
    line markings.
    (d) Dual 2 lane Motorway. Two longitudinal construction joints, one at the lane line
    marking and one at the edge line marking between hard shoulder and left hand
    lane.
    (e) Dual 3 lane Motorway. Three longitudinal construction joints, one at each lane line
    marking and one at the edge line markings between hard shoulder and left hand lane.
    (f) Dual 4 lane Motorway. Four longitudinal construction joints, one at each lane line
    marking and one at the edge line marking between hard shoulder and left hand lane.

    2 Longitudinal constructions joints shall not be more than 150 mm from the centre of the centre
    line, lane line, or edge line marking, with individual widths not exceeding 4.75 m.

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    3 Longitudinal construction joints shall not be located within the left hand lane or dual

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    carriageways. At tapers and other changes in section the construction joint layout shall be
    agreed with the Engineer, and where necessary joints shall also be permitted within 150 mm
    of the mid-point of the traffic lane.
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    END OF PART
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    QCS 2014 Section 06: Roadworks Page 1
    Part 07: Asphalt Plants

    7 ASPHALT PLANTS ................................................................................................. 3


    7.1 ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE .............................. 3
    7.2 ASPHALT PLANTS PRODUCTION CONTROL ...................................................... 4
    7.2.1 Factory Production Control (FPC) 4
    7.2.2 Factory Production Control Quality Plan 4
    7.2.3 Organizational Structure 5
    7.2.4 Internal Audits 5
    7.2.5 Management Review 5
    7.2.6 Document Control 5
    7.3 PRODUCT REALISATION ...................................................................................... 6
    7.3.1 Constituent Materials 6

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    7.3.2 Customer Supplied Product 6

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    7.3.3 Process Control 6
    7.3.4 Handling, Storage and Delivery 7

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    7.3.5 Plant Calibration and Maintenance 7
    7.3.6 Plant Quality Control Laboratory 8
    7.4 ta
    INSPECTION AND TESTING .................................................................................. 9
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    7.4.1 General 9
    7.4.2 Incoming constituent materials 9
    7.4.3 Finished Asphalt Mixture 9
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    7.5 NON-CONFORMITY ............................................................................................. 10


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    7.5.1 General 10
    7.5.2 Non-conformity of Material or Asphalt Mixtures 10
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    7.6 INSPECTION, MEASURING AND TEST EQUIPMENT ......................................... 11


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    7.7 PLANT GENERALLY ............................................................................................. 11


    7.8 ASPHALT PLANT .................................................................................................. 12
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    7.8.1 General 12
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    7.8.2 Automatic Operation 12


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    7.8.3 Cold Bins System 12


    7.8.4 Drier 13
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    7.8.5 Dust Collector 13


    7.8.6 Screens 13
    7.8.7 Hot Bins 13
    7.8.8 Asphalt Binder Storage 14
    7.8.9 Thermometric Equipment 14
    7.8.10 Control of Mixing Time 14
    7.8.11 Pugmill 14
    7.8.12 Temporary Storage of Mix 15
    7.8.13 Safety Requirements 15
    7.8.14 Weigh-Box 15
    7.8.15 Scales or Meters 16
    7.8.16 Plant Control System 16
    QCS 2014 Section 06: Roadworks Page 2
    Part 07: Asphalt Plants

    APPENDICES
    APPENDIX A .................................................................................................................... 17
    APPENDIX B .................................................................................................................... 22
    APPENDIX C .................................................................................................................... 25

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    QCS 2014 Section 06: Roadworks Page 3
    Part 07: Asphalt Plants

    7 ASPHALT PLANTS

    7.1 ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE

    1 Before loading, the bitumen manufacturer shall examine the shipping container and remove
    all remnants of previous cargos that may contaminate the material to be loaded.

    2 The manufacturer shall furnish with each shipment two (2) copies of the delivery ticket
    containing the following:

    (a) Consignees details.


    (b) Net liters.
    (c) Net weight.

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    (d) Type and amount of anti-stripping agent (if any).

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    (e) Identification number (truck, car tank, etc.)
    (f) Destination.
    (g) Date.
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    (h) Loading temperature, and the recommended delivery temperature range.
    (i) Specific gravity.
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    3 The bitumen manufacturer shall deliver a signed Certificate of Compliance to cover the
    quality and quantity of material and the condition of container for each shipment. Test results
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    shall be provided with the shipment.


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    4 Bituminous materials furnished without a Certificate of Compliance should not be introduced


    into the work until the Contractor has had sufficient time to sample and test the delivered
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    materials.
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    5 The delivery tanker shall be insulated with a rock wool or similar material. Burner tubes shall
    be designed so that the bituminous material is evenly heated with no hot spots within the
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    tanker. Temperature gauges shall be calibrated and positioned such that the maximum
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    temperature in the tanker shall be indicated. The temperature of unmodified and modified
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    bitumen during delivery shall be maintained in accordance with the manufacturer


    recommendations. Tankers shall be designed to enable the safe sampling of the bitumen
    from the top of the tanker or from a sampling valve. Sampling shall not take place whilst the
    tank is under pressure.

    6 The Contractor shall obtain acceptance samples of bituminous material according to ASTM
    D140 at the applicable point of acceptance.

    7 For bituminous material used in direct application on the road, samples shall be taken from
    each shipping container at the time of discharge into distributors or other conveyances on the
    project.

    8 For bituminous material initially discharged into storage tanks on the project, samples shall
    be taken from the line between the storage tank and the distributor or the asphalt plant after
    each delivery. Samples shall be taken after a sufficient period of circulation has taken place
    to ensure samples are representative of the material in the storage tank.
    QCS 2014 Section 06: Roadworks Page 4
    Part 07: Asphalt Plants

    9 The manufacturer of bituminous materials shall test all materials produced and the test
    results retained for reference. Each shipment of bituminous material delivered to the asphalt
    plant shall be sampled. The samples shall be numbered consecutively and identified by
    project, type and grade of bituminous material, date of delivery and use. Samples testing
    frequency shall be based on LSA and the Engineer approval.

    10 Each bitumen delivery and storage tank and its associated delivery pipe and control valve
    must be independently and uniquely identified with the tank number.

    11 Storage tanks must also display the grade of bitumen held in the tank.

    12 Adequate and reliable means of gauging the bitumen tank contents and ullage must be
    available at the discharge point.

    13 Vent pipes must be fitted in bitumen tanks and located where they do not pose a risk to any

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    personnel or delivery vehicles and must be kept clear at all times.

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    14 It is recommended that bitumen tanks should be fitted with a correctly designed drain valve to
    enable the safe emptying of the tank for cleaning and maintenance. In the absence of a drain
    valve, a specific risk assessment must be carried out prior to any uplift of product.

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    Samples must not be taken from the bitumen delivery vehicle or hoses at the delivery site
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    unless equipment is fitted to do so safely.
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    16 If there is a requirement to take bitumen samples a purpose designed valve should be


    permanently fitted to the tank (or corresponding pipework).
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    7.2 ASPHALT PLANTS PRODUCTION CONTROL


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    7.2.1 Factory Production Control (FPC)


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    1 The Organization shall establish and operate a permanent factory production control system
    to ensure delivery of the quality requirements of the project specification whilst
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    maintaining a regime of continuous improvement and ensure the competence and


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    training of staff and operators. The Organization shall document and maintain the FPC
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    system in which procedures, regular inspections and tests and/or assessments and the
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    use of the results to control raw and other incoming materials or components, equipment,
    the production process and the product.

    2 A sample plant inspection checklist, which includes the minimum items to be covered as part
    of LSA inspection, Engineer inspection and producer internal audit system, is provided in
    Appendix C.

    7.2.2 Factory Production Control Quality Plan

    1 The Organization shall establish and maintain FPC documentation for each asphalt
    production site used to supply the works.

    2 The FPC documentation shall include a means for identifying and detailing the specific
    processes that directly affect the quality of the asphalt. This shall particularly address:

    (a) Producers organizational structure relating to conformity and quality.


    (b) Document control.
    QCS 2014 Section 06: Roadworks Page 5
    Part 07: Asphalt Plants

    (c) Control procedures for constituent materials and purchaser supplied product.
    (d) Process control
    (e) Requirements for the handling and storage of the product.
    (f) Plant calibration and maintenance.
    (g) Quality control laboratory calibration and maintenance.
    (h) Requirements for inspection and testing of processes and products.
    (i) Procedures for handling non-conformity.

    7.2.3 Organizational Structure

    1 The responsibility, authority and inter-relation of all personnel who manage, perform and
    verify work affecting conformity and quality shall be defined in the quality plan, particularly for

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    personnel who have authority to:

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    (a) Initiate action to prevent the occurrence of product non-conformity.

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    (b) Identify and record any product quality problems.

    2
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    The producer shall identify a person with appropriate authority, knowledge and experience to
    supervise Factory Production Control and to ensure that the requirements of the quality plan
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    are implemented and maintained. The person identified may exercise such supervision over
    a group of plants.
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    3 The management structure shall be documented. Names, affiliations, and positions of


    principal staff shall be listed. The organization chart shall clearly define relationships with
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    other partner organizations where applicable.


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    7.2.4 Internal Audits


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    1 The Organization shall carry out internal audits to verify which activities comply with the
    planned arrangements and to determine the effectiveness of the Factory Production Control
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    system. Audits shall be scheduled on the basis of the status and importance of the activity.
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    The audits and follow up action shall be carried out in accordance with documented
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    procedures. The results of the audits shall be documented and brought to the attention of the
    personnel having responsibility in the area audited. The management personnel responsible
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    for the area shall take timely corrective action on the non- conformities found by the audit and
    shall keep a record of the action taken.

    2 The frequency of such audits shall be that each area of process is audited at least annually.

    7.2.5 Management Review

    1 The system shall be reviewed at least annually by management to ensure its continuing
    suitability and effectiveness.

    7.2.6 Document Control

    1 The producer shall establish and maintain documented procedures to control all documents
    and data that relate to the requirements of these specifications.
    QCS 2014 Section 06: Roadworks Page 6
    Part 07: Asphalt Plants

    2 The producer shall maintain all documents related to daily production quality records, test
    methods, practices, procedures, and specifications.

    3 Records relating to Factory Production Control shall be maintained and accessible by the
    Organization and shall be produced if requested by the Engineer or any authorized audit
    body.

    4 Management review, internal audits, 3rd party assessment, and inspection and testing of
    finished asphalt shall be kept for a minimum of ten years. All other quality records shall be
    kept until at least five years after the completion of the project, or longer as the Organization
    requires.

    7.3 PRODUCT REALISATION

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    7.3.1 Constituent Materials

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    1 Adequate supplies of constituent materials shall be available to ensure that the

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    planned rates of production and delivery can be maintained.

    2 The specification and tolerances for incoming constituent materials shall be established

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    and communicated to suppliers by appropriate traceable and confirmable means.
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    3 The control procedures shall verify that suppliers of incoming materials are capable of
    providing the required quality of materials.
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    4 Different material types or grades shall be transported and stored in such a manner
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    as to avoid intermingling, contamination or deterioration which may adversely affect the


    quality of the product.
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    5 The general requirements of this clause shall be translated into more detailed plant
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    specific requirements within the FPC and include the following:

    (a) Procedures for the control of aggregates delivered to a depot or plant site.
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    (b) Requirements for labelling of storage bays and silos.


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    (c) Requirements for heating, temperature control and insulation of binder tanks, pipes
    and pumps.
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    (d) Requirements for controlling delivery of binders into the correct tanks, including
    stirrers/agitators and labelling of tanks, and the selection of the correct tanks for use.
    (e) Requirements for the control of additives.
    (f) Requirements for the manufacture of polymer modified binders at site by the
    Organization or its supplier, where applicable.

    7.3.2 Customer Supplied Product

    1 Any constituent material supplied by the customer for inclusion in the asphalt shall be
    handled, stored and maintained free of contamination by the Organization.

    7.3.3 Process Control

    1 The FPC quality plan shall include the following items of process control:
    QCS 2014 Section 06: Roadworks Page 7
    Part 07: Asphalt Plants

    2 A description of the flow of materials and the processes carried out on them from receipt at
    the plant to delivery to the job site. This shall incorporate a flow diagram.

    3 A statement of the production control processes necessary to maintain and regulate the
    quality of material in conformity with the specification. This will include the procedure for the
    control of batching instructions.

    4 A schedule for monitoring the performance of the process, which is shown in Table A-1 in
    Appendix A, resulting in a record of plant performance against stated tolerances.

    5 A detailed method statement for the production of polymer modified binder including storage
    and quality control, and the procedure for the handling of nonconforming product.

    7.3.4 Handling, Storage and Delivery

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    1 The FPC quality plan shall contain procedures to ensure that the asphalt mixture is handled,

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    stored, discharged and delivered at the specified temperature range, minimizing segregation

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    and degradation.

    2 The asphalt mixture shall be identifiable and traceable with regard to its production data and

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    can be referenced from information on the delivery ticket from its manufacture to its point of
    installation. The quality plan shall however make clear the point to which the Organizations
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    responsibility for handling storage and delivery extends.
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    3 The quality plan shall describe the characteristics of any hot storage system and define its
    mode of operation. The Organization shall ensure thorough checks, inspections and records
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    that such systems are used correctly and that bituminous mixtures maintain their suitability
    for use.
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    4 Bituminous materials shall not be heated during the process of its manufacture or during
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    construction so as to cause damage to the materials as evidenced by the formation of


    carbonized particles.
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    7.3.5 Plant Calibration and Maintenance


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    1 The FPC quality plan documentation shall identify those items of measuring equipment which
    require calibration and the frequency of such calibration which shall comply with the
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    requirements of QCS 2014, or its revisions, and the contract specification.

    2 Calibration procedures shall be provided, including the permitted tolerances for the
    equipment to remain in service. The quality plan shall state the required accuracy of all plant
    calibrations and shall identify any that require traceability to national reference standards (e.g.
    mass or weight).

    3 The plant shall be maintained to ensure that it continues to be capable of producing asphalt
    to the required specifications and tolerances. Table A-2 gives guidance with regard to
    schedules for calibration and checks.

    4 The FPC quality plan documentation shall identify those items and areas of the plant where
    constant use and wear will affect the quality of production including, but not limited to, the
    dryer drum, hot elevator, screen deck and meshes, hot bins, weighing and mixing apparatus,
    and state the inspection and maintenance schedules for these items in order to maintain
    them to the condition necessary to ensure the quality of production.
    QCS 2014 Section 06: Roadworks Page 8
    Part 07: Asphalt Plants

    5 A maintenance schedule shall be available and maintenance records shall be kept.

    7.3.6 Plant Quality Control Laboratory

    1 The asphalt plant shall have a quality control testing laboratory capable of conducting the
    following tests:

    (a) Sieve analysis (ASTM C117, C136, and D5444).


    (b) Specific gravity for coarse and fine aggregates (ASTM C127, C128).
    (c) Theoretical maximum specific gravity and density of asphalt mixtures (ASTM D2041).
    (d) Quantitative extraction of asphalt binder from asphalt mixtures (ASTM D2172).
    (e) Bulk specific gravity and density of compacted asphalt mixtures (ASTM D1188,
    D2726).

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    2 The asphalt plant laboratory shall have the following:

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    (a) Efficient quality management system.
    (b) Qualified laboratory manager.
    (c) Qualified technicians.
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    (d) Calibrated equipment.

    3 The asphalt plant laboratory shall have a database includes but not limited to the following:
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    (a) Production data.


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    (b) Testing data.


    (c) Materials type and materials traceability to source data.
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    4 The plant laboratory shall keep records of materials and asphalt mixtures properties on a
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    daily basis.
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    5 The laboratory shall maintain a position description for each technical operational position
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    shown on the laboratorys organization chart. Position descriptions shall identify the position
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    and include a description of the duties, required skills, and education and experience
    associated with the position.
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    6 The laboratory shall maintain technical staff training records, qualifications, work experience,
    licensure, certifications, and current position for each supervisory technical staff member.

    7 The laboratory shall maintain a procedure which describes the methods used for laboratory
    personnel training to perform tests in accordance with standard procedures. Records of
    laboratory personnel training shall be maintained.

    8 The laboratory shall maintain a procedure describing the method used to evaluate staff
    competency to ensure that each test covered by the scope of this standard is performed in
    accordance with standard procedures. This description shall include the frequency of
    competency evaluations for each technician and indicate what position or employee is
    responsible for evaluating staff competency and maintaining records. The procedure shall
    ensure that each technician receives a performance evaluation for each test that technician
    performs.
    QCS 2014 Section 06: Roadworks Page 9
    Part 07: Asphalt Plants

    9 The laboratory shall calibrate, standardize, and check all significant equipment associated
    with tests which the laboratory performs.

    10 The laboratory shall have a procedure for the storage, retention, and disposal of test
    samples.

    7.4 INSPECTION AND TESTING

    7.4.1 General

    1 All necessary facilities, equipment and personnel shall be available to carry out the required
    inspections and tests.

    2 Inspection and testing shall be carried out at least as frequently as indicated in Tables A-3 to
    A-7. Sampling shall be randomised so as not to introduce undue bias in the assessment of

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    compliance. Due care shall be taken to adequately cover both large and small volumes of

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    material.

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    3 At least 10% of quality control tests related to constituent materials and finished mixtures
    shall be carried out by an approved thirty party laboratory. Third party testing schedule shall
    be liaised with the Engineer.
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    4 The results of all tests carried out on materials shall be recorded. Tests taken specifically for
    the resolution of problems arising from process control shall be kept separately and need not
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    be used for the purpose of calculating compliance with the technical specifications.
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    5 All sampling and testing shall be carried out in accordance with the relevant standard
    procedures required by the specification.
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    7.4.2 Incoming constituent materials


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    1 Incoming constituent materials shall be inspected and tested using procedures detailed in the
    quality plan and to a schedule complying with this clause and the requirements of QCS 2014,
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    or its revisions, and the contract specification.


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    2 The required inspections of materials in storage shall be maintained to establish that no


    deterioration has occurred.
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    3 Detailed requirements shall be as follows:

    (a) Aggregates: see Table A-3.


    (b) Filler: see Table A-4.
    (c) Additive: see Table A-5.
    (d) Binders: see Table A-6.
    (e) Finished Asphalt Mixture: see Appendix B.

    7.4.3 Finished Asphalt Mixture

    1 The finished asphalt mixture shall be inspected and tested using procedures detailed in the
    quality management system documentation and to a schedule complying with the
    requirements of QCS 2014 and the contract specification.
    QCS 2014 Section 06: Roadworks Page 10
    Part 07: Asphalt Plants

    2 Appropriate statistical records shall be maintained in order to monitor and verify process
    capability and product characteristics.

    3 Individual batch readings shall be recorded as part of the quality records. The plant
    pyrometer shall be calibrated in accordance with ASTM E2847 and checked daily against a
    calibrated laboratory thermometer, the record of which shall be maintained in the plant
    control cabin/office. The temperature of the finished asphalt shall be the average load
    temperature however no batch or part of the load shall exceed the maximum JSM
    temperature for the mix. Measurement shall be in accordance with QCS 2014.

    4 As a regular audit check on the efficacy of the plant quality control laboratory, 10% of
    samples analysed for mix composition by the plant control laboratory shall have a duplicate
    sample analysed in an independent laboratory, which is ISO17025 accredited in related tests.
    The duplicate sampling may be done simultaneously as part of the Organizations other
    testing obligations conducted by an approved independent laboratory. The duplicate results

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    shall be regularly reviewed and any differences falling outside the reproducibility limits

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    published in the test standard applicable to the ASTM test methods employed shall be

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    investigated.

    5 The results of all tests carried out on materials shall be recorded. Tests taken specifically for

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    the resolution of problems arising from process control shall be kept separately and need not
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    be used for the purpose of calculating compliance with the technical specifications.

    6 All sampling and testing shall be carried out in accordance with the relevant standard
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    procedures required by the specification.


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    7 Sampling frequencies, operating compliance level (OCL) and test frequencies are provided in
    Appendix B.
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    7.5 NON-CONFORMITY
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    7.5.1 General
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    1 The producer shall establish and maintain documented procedures to ensure that constituent
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    materials or asphalt mixture which when identified by in-process inspection does not conform
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    to specified requirements is prevented from use or installation. This control shall provide for
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    identification, evaluation, separation from conforming product (when practical) and disposal
    of the nonconforming material or asphalt mixture.

    2 The non-conformance process shall include:

    (a) Constituent materials upon arrival at the plant or storage site.


    (b) Constituent materials in storage.
    (c) The manufacturing process.
    (d) Handling, storage and delivery of the finished product.

    7.5.2 Non-conformity of Material or Asphalt Mixtures

    1 Where non-conforming constituent materials or finished asphalt mixtures are identified, the
    cause of the non-conformance shall be investigated and identified to effect appropriate
    corrective actions to prevent a reoccurrence. Such corrective actions shall be incorporated
    into the FPC quality plan.
    QCS 2014 Section 06: Roadworks Page 11
    Part 07: Asphalt Plants

    2 Corrective actions may involve reworking the material, adjusting the process, redirection to
    another use where it may be acceptable, recycling for further use or rejection and disposal.

    3 The FPC quality plan shall identify the action to be taken in process control when non-
    conforming product is identified from analysis.

    4 The FPC quality plan shall state the process under which the installation contractor and the
    supervising agency will be notified of non-conforming analysis results.

    7.6 INSPECTION, MEASURING AND TEST EQUIPMENT

    1 The Organization shall control, calibrate and maintain suitable measuring and test equipment
    as required by this guidance document and QCS 2014.

    2 To ensure the testing of incoming constituent materials and finished asphalt conforms to the

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    relevant test method specification, the Organization, or where an independent laboratory is

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    employed by the Organization to conduct its quality control testing, shall ensure within the

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    FPC quality plan that the measuring and test equipment used is maintained in a known state
    of calibration and maintenance.

    3
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    The equipment control procedures shall demonstrate the following:
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    (a) Accuracy and frequency of calibration, which should be in accordance with the relevant
    test standard.
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    (b) Equipment is used in accordance with a documented procedure.


    (c) Equipment is uniquely identified.
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    (d) Calibration records to be maintained.


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    7.7 PLANT GENERALLY


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    1 The machinery and tools used in constructing the various items involved in asphalt works
    shall be in good working condition and free of oil and fuel leaks. The Contractor shall
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    maintain and preserve them for the whole duration of the work. The Engineer shall approve
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    the machinery and tools before works begin and the Contractor shall supply adequate
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    quantities of such machinery in order to execute the work with due speed and precision.
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    Equipment approved for use shall not be removed from the Site without the approval of the
    Engineer.

    2 If required the Contractor shall furnish the Engineer with the manufacturer's catalogues,
    specifications and other published data for the equipment and machinery he proposes to use.

    3 On first erecting an asphalt plant and at least once each three months thereafter, the plant
    shall be calibrated by a calibration service organisation approved by the LSA. Production
    shall not be permitted if the weigh batch calibration does not comply with the requirements of
    ASTM D995-95.

    4 The Engineer shall have the right to stop the use of any equipment or plant which he deems
    to be inferior to the quality required or detrimental to the permanent works and to instruct the
    removal of such equipment and to have it replaced by suitable equipment.
    QCS 2014 Section 06: Roadworks Page 12
    Part 07: Asphalt Plants

    5 The Contractor shall immediately comply with such instructions without being entitled to any
    indemnities or extensions as a result of such instructions. The Contractor shall not be
    allowed to use any equipment or plant before obtaining the approval of the Engineer, and the
    Contractor shall undertake to follow sound technical methods in operation and to engage
    skilled and trained operators, mechanics and labour to carry out the works. The Engineer
    shall have the right to expel any operators, mechanics or labour and to instruct suitable
    replacement thereof at any time he deems such action is necessary.

    6 The Contractor shall comply with any special plant requirements published by the concerned
    authority.

    7.8 ASPHALT PLANT

    7.8.1 General

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    1 All plant used by the Contractor for the preparation of asphalt hot mixes shall be batch type
    plants conforming to the requirements as detailed below.

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    2 The Engineer may permit the use of continuous drier drum type asphalt plants after a fully
    detailed technical submission by the Contractor itemising the differences from the

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    specification. In such cases after approval of the technical submission the Contractor shall
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    carry out a full scale laying trial with testing of the hot and laid mix and monitoring of the plant
    operation by the Engineers staff to assess the suitability of the proposed plant.
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    3 No laboratory verification or plant trial shall be carried out by the LSA unless an automatic
    compaction apparatus is available at the producers laboratory.
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    7.8.2 Automatic Operation


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    1 The plant shall be designed, co-ordinated and operated so as to continually produce an


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    asphalt mix within the job mix tolerances specified.

    2 The plant shall be equipped and operated so that the proportioning of the hot aggregate, filler
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    and bitumen, together with the dry and wet mixing cycles are all controlled automatically.
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    Positive interlock shall be provided so that proportioning, mixing and discharge are
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    accomplished by one operation without manual control of the separate phase.


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    3 The use of manual and semi-automatic plants for the production of asphalt is not permitted
    unless specific approval is given in writing by the Engineer.

    7.8.3 Cold Bins System

    1 The plant shall include a sufficient number of cold storage bins so that there is at least one
    bin for each different stockpile of material being used.

    2 Intermixing of material from different stockpiles in one bin or on the ground before putting into
    the bin is prohibited.
    QCS 2014 Section 06: Roadworks Page 13
    Part 07: Asphalt Plants

    3 The cold bins and loading equipment used shall be compatible to prevent overflow between
    the bins. Baffle plates shall also be used between bins to prevent overflow of one bin into
    another. Each cold bin shall include an accurate means for continuously feeding the required
    amount of mineral aggregate so that uniform production is achieved. The settings on the cold
    bins shall be approved by the Engineer and shall be checked and calibrated as often as he
    may deem necessary to ensure their continued accuracy. Change of settings shall be made
    only with the approval of the Engineer.

    7.8.4 Drier

    1 A drier of satisfactory design shall be provided. The drier shall be capable of uniformly drying
    and heating the aggregate to the moisture and temperature required without leaving any
    visible burned oil or carbon residue on the aggregate when discharged from the drier.

    7.8.5 Dust Collector

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    1 The plant shall be provided with a dust collector designed to waste, or to return all or part of

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    the material collected to the asphalt plant.

    2 The asphalt plant shall have an efficient fugitive emission collection and control system to

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    control dust or fume emissions from the drying, screening, weighing and mixing operations.
    qa
    The collection system shall be so designed to prevent the emission of dust and fumes into
    the atmosphere in accordance with the environmental standards of Qatar.
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    3 The collected dust from the drying process shall pass through a coarse collector which will
    pass the coarse particles, substantially greater than 0.075mm, back to the hot elevator or to
    se

    a silo for the controlled return to the asphalt mix. The reclaimed dust substantially less than
    0.075mm shall be collected and passed into a storage silo for the controlled return as mineral
    er

    filler to the asphalt mix through the filler weighbox or sent to waste.
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    4 The plant shall be equipped with a filler silo for recovered filler. An additional dry storage silo
    shall be provided for imported mineral filler with a provision of a separate weighing hopper to
    proportion this filler into the mix.
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    7.8.6 Screens
    et

    1 Plant screens shall be capable of screening all aggregates to the specified sizes and
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    proportions. They shall have capacities equal to or greater than the maximum rated capacity
    of the plant. They shall have an operating efficiency such that the aggregate deposited in any
    bins shall not contain more than 10 % oversize or undersize material. This screen tolerance
    shall not invalidate the job mix tolerances specified.

    7.8.7 Hot Bins

    1 The plant shall include at least three storage bins for hot aggregate of sufficient size to supply
    the pugmill when it is operating at full capacity. They shall be arranged to ensure separate
    and adequate storage of appropriate fractions of the aggregate. Each compartment shall be
    provided with an overflow pipe that shall be of such size and at such location as to prevent
    any backing up of material into other bins or against the screens. Bins shall be so
    constructed that samples can be readily obtained therefrom. The hot bins shall be equipped
    with continuous level indicators to provide information about the level of each ingredient of
    the JMF and to avoid shortage or overflow of aggregate from one bin to another.
    QCS 2014 Section 06: Roadworks Page 14
    Part 07: Asphalt Plants

    7.8.8 Asphalt Binder Storage

    1 Tanks for storage of asphalt binders shall be equipped for heating the material using positive
    and automatic control at all times, to a temperature within the specified range. The heating
    shall be accomplished by hot thermal oil, electricity or other approved means such that no
    direct flame shall come in contact with the bitumen or heating tank.

    2 The circulating system for the asphalt binder shall be of adequate size to ensure proper and
    continuous circulation during the entire operating period. Suitable means shall be provided
    either by double jacketed steam or hot oil or other insulation for maintaining the specified
    temperature of the bituminous material in the pipeline, meters, weigh buckets, spray bars,
    and other containers and flow lines.

    3 The storage tank capacity shall be sufficient for at least one day's operation. Circulation
    return lines to the asphalt storage tanks should be submerged to the same elevation in the

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    storage tanks as the feeder line. Two or three vertical slots may be cut in the return line

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    above the high level mark to break vacuum when reversing the pump.

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    4 The Contractor shall provide a sampling outlet in the asphalt binder feed line connecting the
    plant storage tanks to the asphalt binder weighing or metering box. The outlets shall consist

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    of valves installed in such a manner that samples may be withdrawn slowly at any time during
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    plant operation. The locations of the sampling outlets shall be readily accessible and free
    from obstructions. Drainage receptacles shall be provided for flushing the outlets before
    sampling.
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    7.8.9 Thermometric Equipment


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    1 An armoured thermometer reading from 38 C to 204 C shall be fixed in the bituminous feed
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    line at a suitable location near the discharge valve. Similar devices shall be fixed in the
    heating and storage tanks.
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    2 The plant shall be further equipped with either an approved dial-scale, mercury-actuated
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    thermometer, an electric pyrometer, or other approved thermometric instruments placed at


    the discharge chute of the drier and in the hot fines bin so as to register automatically or
    it
    et

    indicate the temperature of the heated aggregates. For better regulation of the temperature
    of the aggregates, replacement of any thermometer by an approved temperature recording
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    apparatus may be required by the Engineer and he may further require that daily temperature
    charts be submitted to him by the Contractor.

    7.8.10 Control of Mixing Time

    1 The Plant shall be equipped with positive means to govern the time of mixing and to maintain
    it constant unless changed at the direction of the Engineer.

    7.8.11 Pugmill

    1 The batch mixer shall be an approved twin pugmill type, capable of producing a uniform
    mixture within the job-mix tolerances. It shall be so designed as to permit a visual inspection
    of the mix. The mixer capacity shall be not less than 600 kg per batch and shall be so
    constructed as to prevent leakage of contents.
    QCS 2014 Section 06: Roadworks Page 15
    Part 07: Asphalt Plants

    2 The bitumen system shall deliver an even flow of binder into the mixer to ensure an even
    distribution of bitumen binder throughout the mix during the wet mixing cycle.

    3 The mixer shall be fully enclosed with sufficient air extraction to prevent emissions of dust
    and fumes. The mixing cycle shall be controlled such that from charging of the mixer until the
    closing of the mixer door at the completion of the cycle there shall be no leakage of
    aggregate, filler or bitumen from the weighing hoppers. The system shall permit a dry mixing
    period, defined as the interval of time between opening of the weigh box gate and the start of
    application of bitumen, if required by the mixing process.

    4 The wet mixing period is defined as the interval between the discharge of the bitumen binder
    into the mixer and the mixer gate is opened to discharge the mix, and shall be not less than
    30 seconds. The wet mix time shall be capable of being incrementally set at intervals of not
    more than five seconds up to a wet mix time of three minutes. A mechanical batch counter
    shall register the completely mixed batches.

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    5 The mixer shall be equipped with a full set of mixer paddles in a suitable arrangement, in

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    accordance with the manufacturers specification, to produce a proper and uniformly mixed
    batch. All paddle arms and tips, and mixer liners shall be in good condition. Mixing shall
    cease if any mixer arms or tips are missing, and shall not resume until replaced and
    inspected.
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    7.8.12 Temporary Storage of Mix
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    1 Plants may be equipped with skips or elevators for delivering batched mix to hoppers or silos
    before discharging to hauling units. The skips or elevators shall not be sprayed with diesel or
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    other solvents; where necessary they may be sprayed with a minimum amount of lime water,
    soap or detergent solution. Hoppers or silos shall be of such design that no segregation or
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    loss in temperature of the mix occurs.


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    7.8.13 Safety Requirements

    1 Adequate and safe stairways to the mixer platform and guarded ladders to other plant units
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    shall be placed at all points required for accessibility to all plant operations. Accessibility to
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    the top of truck bodies shall be provided by means of a platform or other suitable device to
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    enable the Engineer to obtain mixture temperature data. To facilitate handling scale
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    calibration equipment and sampling equipment, a hoist or pulley system shall be provided to
    raise or lower the equipment from the ground to platform or vice-versa. All gears, pulleys,
    chains, sprockets and other dangerous moving parts shall be thoroughly guarded and
    protected. Ample and unobstructed passage shall be maintained at all times in and around
    the truck loading space. This space shall be kept free from drippings from the mixing
    platform.

    2 Accessibility to the top of loaded truck body shall be provided by means of a platform to
    enable obtaining asphalt mixture samples and temperature readings and to check truck body
    condition. All necessary safety measures shall be provided for accessing the top of loaded
    truck body.

    7.8.14 Weigh-Box

    1 The plant shall include means for accurately weighing each size of aggregate in a weigh-box
    or hopper, suspended on scales, ample in size to hold a full batch without hand raking or
    running over.
    QCS 2014 Section 06: Roadworks Page 16
    Part 07: Asphalt Plants

    2 The weigh-box or hopper shall be so constructed that they will not be thrown out of alignment
    or adjustment. All edges, ends and sides of weighing hoppers shall be free from contact with
    any supporting rods and columns or other equipment that will in any way affect the proper
    functioning of the hopper.

    3 There shall also be sufficient clearance between hoppers and supporting devices to prevent
    accumulations of foreign materials. The discharge gate of the weigh-box shall be so hung
    that the aggregate will not be segregated when dumped into the mixer and shall close tightly
    when the hopper is empty so that no material is allowed to leak into the batch in the mixer
    during the process of weighing the next batch.

    4 Weighing boxes and hoppers shall be free hanging and placed on high precision load cells or
    strain gauges.

    7.8.15 Scales or Meters

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    1 Scales or meters used for proportioning aggregates, mineral filler and bitumen shall be

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    accurate to 1 % of the indicated quantity. Scales and meters shall be substantially
    constructed. Scales and meters that require frequent adjustment shall be replaced. Scales
    shall be constructed and located so as to prevent vibration in the dial pointer.

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    Weighing sequence of hot aggregates shall progress from coarse to fine.
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    3 Bituminous material shall be automatically proportioned by either weighing or metering. The
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    minimum gradation shall be not more than 1 litre or 1 kg. Bituminous scales and weigh
    buckets shall be such that the required amount of bitumen is provided in a single weighing
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    and delivered to the pugmill without loss due to overflow, splashing or spillage.
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    4 Bituminous weigh buckets shall be satisfactorily insulated to prevent loss of heat in the
    bitumen or accumulation of bitumen in the bucket. Bituminous metering devices shall be
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    rotating positive displacement pumps and shall be capable of providing the designated
    quantity of material for each batch.
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    5 All scales and meters shall be approved by the Engineer and shall be checked and calibrated
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    as detailed in Clause 5.3. Production shall not be permitted if the weight batch calibration
    et

    does not comply with the requirements of ASTM D955-95.


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    7.8.16 Plant Control System

    1 The asphalt plant operations shall be fully automated and connected to a centralized control
    system. Preferably, the plant operating software shall be capable to store the detailed
    production history.
    QCS 2014 Section 06: Roadworks Page 17
    Part 07: Asphalt Plants

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    APPENDIX A

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    QCS 2014 Section 06: Roadworks Page 18
    Part 07: Asphalt Plants

    Table A-1: Process control minimum inspection schedule

    Control Area Inspection/Test Purpose Minimum frequency


    Identify
    contamination,
    Aggregate stockpiles As FPC quality plan Daily
    intermingling, level
    ground for tipping,
    stock availability
    Ensure correct
    Cold feed bins As FPC quality plan feeding to plant and Weekly
    maintenance of bins
    Maintenance
    inspection to ensure Monthly or as
    Aggregate dryer As FPC quality plan FPC quality plan
    effective heating and
    drying

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    Dried Control for Continuously

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    Aggregate
    heated temperature conformance in production

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    aggregate
    Identify mechanical Weekly or as
    Aggregate screens As FPC quality plan
    and physical defects FPC quality plan

    As FPC quality plan ta


    Identify mechanical
    and physical defects
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    Hot aggregate bins Weekly
    Check screening
    Hot bin gradations
    efficacy
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    Identify mechanical
    and physical defect
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    Weighing apparatus As FPC quality plan Check weighing Weekly


    efficacy against truck
    er

    scale
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    Check storage
    Tank temperature Daily
    conformance
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    Bitumen In accordance with


    As FPC quality plan
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    Binder properties storage


    or in case of doubt
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    recommendations
    Temperature Test of To ascertain the
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    monitoring accuracy equipment is


    equipment for comparison Weekly
    functioning correctly
    drying/heating and with calibrated
    asphalt mix reference
    process thermometer
    Each batch or
    Asphalt mix Mix temperature Ensure temperature
    continuously in
    conformance
    production
    QCS 2014 Section 06: Roadworks Page 19
    Part 07: Asphalt Plants

    Table A-2: Minimum plant calibration and check requirements

    Item of Plant Inspection/Test Purpose Minimum frequency


    To ensure that
    Visual inspection as
    weighing equipment is Daily
    described in procedures
    functioning correctly
    Weighing
    equipment To ensure accuracy 1
    a) on installation
    Testing of weighing within quality plan b) every 3 months
    accuracy - calibration requirements c) in case of doubt.

    To ensure that
    First batch of the day
    dispenser is
    Organoleptic* inspection containing admixture
    Admixture/additive functioning correctly
    dispensers To ensure accuracy 1
    a) on installation
    Test for accuracy as
    within quality plan b) every 3 months
    described in procedures.

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    requirements c) in case of doubt.

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    Comparison of the actual To ensure accuracy 1
    a) on installation

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    Flow meters amount with the metered within quality plan b) every 3 months
    amount by reconciliation requirements c) in case of doubt.

    Comparison of actual
    mass of constituents in
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    To ensure the batching
    a) on installation
    1
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    Batching system the batch with the accuracy in
    b) every 3 months
    (on batch plants) intended mass using the accordance with the
    c) in case of doubt.
    method prescribed in the quality plan
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    quality plan
    Comparison of actual
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    mass in a measured To ensure the 1


    a) on installation
    Proportioning period of time with the accuracy in
    b) every 12 months
    system (cold feed) intended mass using the accordance with the
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    c) in case of doubt.
    method prescribed in the quality plan
    quality plan
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    To ensure the
    Visual as described in
    equipment is Daily
    procedures
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    functioning correctly
    Temperature
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    Test of accuracy To ensure the


    monitoring
    comparison with
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    equipment equipment is Weekly


    calibrated reference functioning correctly
    (infrared
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    thermometer 1
    pyrometer) To ensure correct a) on installation
    Test of accuracy - temperatures are b) every 12 months
    calibration recorded c) in case of doubt.

    Temperature To ensure the


    Visual as described in
    monitoring equipment is Daily
    procedures
    equipment (contact functioning correctly
    probe or 1
    thermocouple for To ensure correct a) on installation
    drying heating Test of accuracy - temperatures are b) every 3 months
    process) calibration recorded c) in case of doubt.
    QCS 2014 Section 06: Roadworks Page 20
    Part 07: Asphalt Plants

    Table A-3: FPC Inspection and test guidance for aggregate stockpiles

    Inspection/Test Purpose Minimum frequency

    To check suitability for As required by QCS 2014,


    Tests for aggregate properties
    intended use or its revisions

    Each size: Weekly


    Tests for aggregate consistency To check consignment quality Each consignment: in
    by sieve analysis case of doubt

    To check consignment is
    Inspection of delivery ticket as ordered and from Each delivery
    correct source

    Table A-4: FPC inspection and test guidance for Filler

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    Inspection/Test Purpose Minimum frequency

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    Tests for filler properties To check suitability As required by QCS 2014,
    for intended use or its subsequent revisions

    Tests for filler consistency To check consignment


    or production quality ta Gradation: Weekly
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    Plasticity: Weekly
    Filler: Non plastic
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    Appropriate tests to To confirm characteristics Each delivery or weekly


    determine specified of product or check for reclaimed filler dust
    properties compliance with
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    specification
    Inspection of delivery ticket To check consignment is Each delivery
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    as ordered and from


    correct source
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    Table A-5: FPC inspection and test guidance for additives


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    Inspection/Test Purpose Minimum frequency


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    Appropriate tests to To confirm characteristics a) Source approval prior


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    determine intrinsic of product or check to initial use and


    properties compliance with b) as stated in the quality plan
    specification
    Inspection of delivery ticket To check that consignment Each delivery
    is as ordered and from the
    correct source

    Organoleptic* For comparison with Each delivery, if


    check of normal appearance practicable; otherwise in
    consignment accordance with quality
    plan.
    QCS 2014 Section 06: Roadworks Page 21
    Part 07: Asphalt Plants

    Table A-6: FPC Inspection and test guidance for bitumen binder

    Inspection/Test Purpose Minimum frequency


    Tests for bitumen properties To check suitability for As required by QCS 2014 and
    intended use project particular specification

    Inspection of delivery ticket To check consignment is as Each delivery or production batch


    ordered and from the correct
    source
    Temperature To check that binder is within (a) Each delivery or production
    specified temperature limits batch
    (b) Each tank recorded daily

    Grade Properties (60/70) To assess compliance with 1 per 450 tons of binder delivered
    specification in normal production

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    Grade Properties (PG76- 10) To assess compliance with 1 per 450 tons of binder delivered
    specification in normal production

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    Prior to production if stored for
    more than 3 days without further
    deliveries or production batches
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    Organoleptic* Check For comparison with normal Each delivery or daily survey of
    perceptible properties tanks
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    Table A-7: FPC minimum inspection/test frequencies for product quality control
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    Inspection/Test Purpose Minimum frequency


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    Organoleptic* check on For comparison with normal Every load


    mixed asphalt appearance with regard to
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    grading, evenness of mixing


    and adequacy of binder
    coating
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    Suitability of delivery To check adequacy of a) Prior to first use


    vehicles by visual insulation b) In case of doubt.
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    assessment
    Cleanliness of delivery To avoid contamination Every load prior to loading
    vehicles by visual To control use of release agent
    assessment

    Mixed asphalt temperature To assess conformity a) As required under Table


    1
    b) Whenever samples
    are taken
    Grading and binder content To assess conformity In accordance with QCS
    2014
    Other characteristics included To assess conformity In accordance with QCS
    in technical specifications 2014

    * Organoleptic check: a broader evaluation made with the senses: sight, touch, smell, hearing etc. rather
    than a visual inspection.
    QCS 2014 Section 06: Roadworks Page 22
    Part 07: Asphalt Plants

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    APPENDIX B

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    QCS 2014 Section 06: Roadworks Page 23
    Part 07: Asphalt Plants

    MINIMUM SAMPLING FREQUENCIES AND TOLERANCES FOR THE FACTORY PRODUCTION


    QUALITY CONTROL OF FINISHED ASPHALT
    General

    1 This Appendix includes sampling frequencies and tolerances for mixture composition for use
    in the evaluation of conformity of mixed asphalt during production. It is consistent with QCS
    2014 but is specifically intended as guidance for the Organization (Asphalt Producer) to
    maintain the quality control of the finished asphalt mixture at the point of manufacture and
    does not impede on the requirements of QCS 2014, or its revisions, or the contract
    specification. The sampling and frequencies are the minimum that should be considered for
    control but it is to discretion of the Organization to ensure sufficient samples, tests and
    assessments are made in order for the asphalt mixture conforms to specification
    requirements.

    .
    2 The properties of asphalt mix characteristics shall conform to the requirements of QCS 2014

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    and the contract specification. Should these not properties be found not to conform to the Job
    Mix Formula the design should be assessed.

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    3 The guidance provides for three levels of minimum frequency. The minimum frequency which
    shall be carried out for all production circumstances and higher frequencies which are
    ta
    appropriate where it is necessary to give a greater assurance of consistency where the
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    measured level of conformity has decreased.

    4 A guide to assessment of production quality control test conformity is given.


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    Testing tolerances and conformity assessment


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    1 Asphalt mixture composition Job Mix Tolerances shall be in accordance with QCS 2014, as
    indicated in Table B.1:
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    Table B.1: Job Mix Tolerances


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    Intermediate
    Description Base Course Wearing Courses
    Course
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    Aggregate retained on 4.75mm


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    5% 4% 4%
    sieve or larger
    et

    Aggregate passing 4.75mm sieve


    4% 3% 3%
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    and retained on 850m sieve


    Aggregate passing 850m sieve
    3% 2% 2%
    and retained on 75m sieve

    Aggregate passing 75m sieve 1.5 % 1.0 % 1.0 %

    Binder Content 0.3 % 0.2 % 0.2 %

    Operating Compliance Level

    1 The Operating Compliance Level (OCL) shall be applicable to each single plant and shall be
    determined on an ongoing basis from the number of non-conforming compositional test
    results within the last 32 analyses of all asphalt mixtures tested. In addition, the OCL shall
    take into account the consistency of production with assessment of the mean deviation from
    target as detailed in Table B.2.
    QCS 2014 Section 06: Roadworks Page 24
    Part 07: Asphalt Plants

    2 In the event of 5 or more of the previous 32 results being non-conforming, and/or variance of
    the mean deviation from target from the prescribed tolerances, the plant shall be subject to
    an immediate and comprehensive review of equipment and procedures.

    Mean Deviation from Target

    1 For each analysis the deviation from target shall be determined for each of the sieves sizes
    and binder content indicated in Table B.1. A running mean of the deviations for the last 32
    analyses of each asphalt mixture shall be maintained.

    2 Should the running mean of the deviations exceed the values stated in Table B.2, this shall
    be deemed to be non-conforming asphalt mixture in accordance with Clause 25.4.2 and the
    appropriate corrective quality control action taken. The Operating Compliance Level shall be
    lowered by one level for as long as the mean deviation stays outside tolerance.

    Table B.2: Mean deviation from target tolerances

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    Description Base Course Intermediate Wearing Course

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    Course
    Aggregate passing 19 mm 4 3 -

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    Aggregate passing 12.5 mm - 3
    Aggregate passing 9.5 mm 4 3 3
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    Aggregate passing 4.75 mm
    3 2 2
    (Superpave)
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    Aggregate passing 2.36 mm


    3 2 2
    (Marshall)
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    Aggregate passing 75 m sieve 1.5 1.0 1.0


    Soluble Binder Content 0.3 0.2 0.2
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    Test Frequency

    1 The frequency for sampling shall be determined weekly and shall be maintained at the
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    operating compliance level minimum frequency indicated in Table B.3.


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    Table B.3: Determination of Operating Compliance Level and Sampling Frequency


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    Number of nonconforming Operating Compliance


    Minimum Sample Frequency
    analyses in last 32 Level

    0-2 A 1 per 250t per mix or part thereof

    3-6 B 1 per 200t per mix or part thereof

    6 C 1 per 100t per mix or part thereof

    2 New plants commencing production, plants restarting after relocating, a major repair or
    overhaul, or those recommencing commercial production after a period exceeding 3 months
    cessation shall operate under OCL until 32 results have accumulated after which the
    frequency shall revert to the OCL achieved.
    QCS 2014 Section 06: Roadworks Page 25
    Part 07: Asphalt Plants

    APPENDIX C

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    QCS 2014 Section 06: Roadworks Page 26
    Part 07: Asphalt Plants

    Table C-1: Sample of plant inspection checklist

    Aggregate Stockpiles Yes No


    Are aggregate stockpiles separated by walls or clear space
    1 with signed labelling?
    Are the stockpiles free of significant contamination and
    2 segregation? (Plant drain-out aggregate is acceptable if the
    aggregate size is similar and uncoated.)
    Is the aggregate in good condition with no signs of degradation
    3 on the stockpile due to vehicle/plant movements?

    Is the truck tipping area at the stockpile level? (Non-level


    4 surfaces can cause trucks to tip over.)
    Do the aggregate delivery and test records conform to the
    5 approved mix designs?

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    Have the aggregates been sampled and tested in accordance
    6 with requirements?

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    Aggregate Cold Feed
    Has each aggregate size its own designated and labelled
    1 bin/hopper?
    ta
    Are bins/hoppers in good condition with no holes, with bin wall
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    2 divider plates between each?
    Is aggregate overflow between hoppers being prevented by
    3 divider plates?
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    If meshes (grizzlies) are fitted over the bins/hoppers, are they


    4 in reasonable condition and fit for purpose?
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    Are the feeder gates, feeder belts and vibrators in good


    5 condition?
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    Are there no-flow paddles/sensors on each feeder and are


    6
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    they working?
    7 Date of the last feeder calibrations:
    Is the aggregate collecting conveyor in good condition, with no
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    8 holes or splits, or evidence of tracking (side movement) and


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    the belt scrapers are in good order?


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    Dryer
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    Is there any significant aggregate spillage under the dryer


    1 conveyor, the dryer drum or around the base of the hot
    elevator?
    Are the dryer lifters and flights are in good condition without
    2 undue bending or deformation and none missing. (when dryer
    is cold and stopped)
    Is the drum exit chute temperature pyrometer, thermocouple
    3 or probe clean, working and in calibration?
    4 Date of last pyrometer, thermocouple or probe calibration:
    Has the drum exit chute Date:
    temperature equipment been
    checked recently with a Drum chute: C
    5 referenced laboratory probe?
    Laboratory probe:
    C
    QCS 2014 Section 06: Roadworks Page 27
    Part 07: Asphalt Plants

    Dust Collection
    Does the pre-skimmer or knockout box return the collected
    1 fine sand to the plant hot elevator?
    a: returned to a silo for re-use?

    Is the bag house b: directly fed back into the asphalt


    2
    extracted dust:- plant?

    c: wasted?
    Does the laboratory monitor the gradation of the coarse pre-
    3 skimmer or knockout box fines and bag house filler?
    4 Is there a dust emission monitoring system on the plant?
    5 Date of last certified plant stack emission test?
    Is the plant stack emission is visually clean with no obvious

    .
    6

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    dust or smoke??

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    Aggregate Screening

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    1 Is there any spillage around the screen deck area?
    2 Did the last screen inspection indicate any defects?
    3 Date of last screen deck inspection:
    ta
    Are there any signs of damage or wear, especially adjacent to
    qa
    4 screen bearings or shafts?
    Is there any significant dust emission from the screen housing
    5 lids, covers or doors?
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    Is there any evidence of holes, splits or tears in the screen


    meshes and is there any apparent and significant pegging or
    se

    6
    blockages?
    Are there any loose screen meshes that need tightening or
    er

    7 support bars that are loose and need welding?


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    Is there evidence of side seal seepage which could


    8 contaminate screened aggregate or wear other parts?
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    Hot Aggregate Bins


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    Is there any indication of hot bin oversize or undersize in hot


    1
    et

    bin drain-outs?
    2 Bin 1 Aggregate size 0 / X mm
    m

    3 Bin 2 Aggregate size X / X mm


    4 Bin 3 Aggregate size X / X mm
    5 Bin 4 Aggregate size X / X mm
    6 Bin 5 Aggregate size X / X mm
    7 Bin 6 Aggregate size X / X mm
    Are the individual hot stone bin overflow chutes/pipes blocked
    8 or damaged?
    Are there holes or damaged seams or welds in the hot bin
    walls, especially in the corners and in the lower half of the
    9
    bins?

    Do the hot stone bin doors stick or seize? Is there evidence of


    holes in or leakage from the doors?
    10
    QCS 2014 Section 06: Roadworks Page 28
    Part 07: Asphalt Plants

    Weighing and Measuring Apparatus


    Are the calibrations of the aggregate, filler and bitumen
    1 weighing apparatus current and in date?
    2 Aggregate weighing apparatus calibration date:
    3 Bitumen weighing apparatus calibration date:

    4 Filler weighing apparatus calibration date:

    5 Mixed asphalt pyrometer calibration date:


    Date:
    Has the mixed asphalt pyrometer been
    6 checked recently with a referenced Pyrometer: C
    laboratory probe? Laboratory probe: C
    Weighing efficacy:
    Do the printed batch weights equal the weight indicators and

    .
    1 are total load batch weights similar to the truck scale net

    l
    .l.
    weight?
    Does the bitumen bucket/kettle pass the static load test?

    rw
    (Hold a fully weighed batch of bitumen for at least 30 seconds
    2 and note any change in weight. Repeat when empty and note
    any major change in tare)
    ta
    Does the aggregate and filler weighing apparatus pass the
    qa
    3 static load test?
    Is there any bitumen seepage or leakage from the charge and
    the discharge pipes, and the butterfly valve underneath on
    as

    4
    direct gravity discharge bitumen bucket/kettle systems?
    Is the bitumen bucket/kettle adequately insulated and heated?
    se

    Seepage or leakage from the charge and the discharge


    5 pipes? Check the butterfly valve underneath for direct gravity
    er

    discharge systems.
    Bitumen Storage and Pumping
    ov

    Where fitted, are breather vents clear on the bitumen weigh


    1 bucket/kettle and delivery pipe to the mixer?
    o

    Are the bitumen tanks and are all tanks clearly labelled
    it

    2 according to the grade of binder stored?


    et

    Are stored binder tank temperatures compliant with


    3 specification or supplier recommendations?
    m

    Where PMB is stored, are the stirrers operational and in good


    4 condition?
    Is there a supplier defined procedure for the storage and use
    5 of polymer modified binders?
    Are all tanks, pipes, pumps and flow meters properly
    6 insulated and the surrounds clean and in good order?
    Is there any evidence of excessive bitumen or oil
    7 seepage/leaks from pump(s), valves or manifolds?
    Are bitumen tank temperatures monitored and recorded daily
    8 by the plant staff?
    Are the bitumen binders tested for foaming when heated to
    9 175C?
    Is there a control or procedure for tank/binder grade selection
    10 according to asphalt mix recipe to avoid using the incorrect
    grade?
    QCS 2014 Section 06: Roadworks Page 29
    Part 07: Asphalt Plants

    Asphalt Mixing
    Are the weighing apparatus and mixer external surrounds in
    1 clean and good order with no apparent seepage or leakage of
    aggregate, filler or bitumen?
    Are inspection hatches secure and sealed to prevent dust
    2 emission?
    Are electric cables, hydraulic and air lines well maintained and
    3 in good order?
    Are all mixer arms, paddles and tips, liners and door seals
    4 present and in good condition?
    Is the aggregate weighing sequence, coarse size to fine size?
    5
    Is there excessive overflow from the aggregate overflow
    6 chutes?

    .
    7 Check the required batch weights on the mix card.

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    .l.
    Are batch deviations within acceptable guide tolerance?
    8

    rw
    9 Batch aggregate component 1.5% of total batch weight

    10 Bitumen deviation 0.1% of total batch weight

    11 ta
    Mineral filler deviations 0.1% of total batch weight
    qa
    Are the in-flight adjustments being made automatically by the
    12 plant control system?
    as

    13 What is the delay time after aggregate discharge for bitumen: sec.
    What is the delay time after aggregate discharge for filler:
    se

    14 sec.
    What is the total wet mixing time in seconds?
    er

    (From the complete discharge of the bitumen and filler to the


    15 sec.
    emptying of the finished batch)
    ov

    On completion of the mixing cycle, does the mixer fully


    16 empty?
    o

    On visually inspecting single batches of asphalt, is the


    it

    17 appearance consistent from side to side and front to back,


    et

    and not segregated?


    Does each batch conform to the mix temperature
    m

    18 specification requirement?
    Does the plant indicated mixed asphalt temperature
    19 correspond with a laboratory check?
    Where used, is the skip hopper acceptably clean?
    20

    Are the empty hot storage silos acceptably clean without cold
    21 asphalt sticking to the sides and corners?
    Loading
    Are all trucks acceptably clean prior to loading without any
    1 evidence of diesel being used as a release agent?

    Are all trucks equipped with load cover sheets or canvasses?


    2
    Are the loaded trucks free of significant segregation?
    3
    QCS 2014 Section 06: Roadworks Page 30
    Part 07: Asphalt Plants

    Is the asphalt temperature acceptably consistent and within


    4 range tolerance throughout the load front to back?
    Has the correct delivery ticket been issued to the driver with
    5 accurate asphalt description, truck reference or number, site
    address, driver name, and ticket number?
    Is the plant sampling technician equipped with all necessary
    PPE including safety helmet, steel-capped boots, overalls,
    6 gloves, hi-visibility jacket, and protective eye glasses?

    Are the plants sampling procedures being following by the


    7 technician to ensure a representative sample?
    (Ask for and retain a copy of the sampling procedures.)

    Are plant sample details, including truck delivery details, are


    8 recorded on each plant sample?

    . l
    Request plant compliance rate for each product supplied to the

    .l.
    9 project or contract for record purposes.

    rw
    ta
    qa
    as

    END OF PART
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Roadworks Page 1
    Part 08: Recycled and Stabilised Road Materials

    8 RECYCLED AND STABILISED ROAD MATERIALS ............................................................ 2


    8.1 GENERAL 2
    8.1.1 SCOPE 2
    8.1.2 REFERENCES 2
    8.1.3 DEFINITIONS 3
    8.1.4 SUBMITTALS 4
    8.1.5 QUALITY ASSURANCE 4
    8.2 COLD STABILISED MATERIAL - GENERAL 4
    8.3 MATERIALS 5
    8.4 CEMENT TREATED BASE (CTB) 6
    8.4.1 PREPARATION AND MIX DESIGN FOR CEMENT TREATED BASE 6
    8.4.2 SITE TRIALS FOR CEMENT TREATED BASE AND BITUMEN STABILISED MATERIAL 7
    8.4.3 INSITU STABILISATION AND COMPACTION OF CEMENT TREATED BASE 7

    .
    8.4.4 EXSITU PRODUCTION OF CEMENT TREATED BASE 9

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    .l.
    8.4.5 LAYING AND COMPACTION OF CEMENT TREATED BASE 9
    8.4.6 JOINTS IN CEMENT TREATED BASE 10

    rw
    8.4.7 SAMPLING AND TESTING - CEMENT TREATED BASE 10
    8.4.8 EVENNESS AND LEVEL 12

    ta
    8.5 BITUMEN STABILISED MATERIAL (BSM) 12
    8.5.1 PREPARATION AND MIX DESIGN FOR BITUMEN STABILISED MATERIAL 12
    qa
    8.5.2 SITE TRIALS FOR BITUMEN STABILISED MATERIAL 13
    8.5.3 INSITU STABILISATION AND COMPACTION OF BITUMEN STABILISED MATERIAL 13
    8.5.4 EXSITU PRODUCTION OF BITUMEN STABILISED MATERIAL 14
    as

    8.5.5 LAYING AND COMPACTION OF BITUMEN STABILISED MATERIAL 15


    8.5.6 JOINTS IN BITUMEN STABILISED MATERIAL 16
    8.5.7 SAMPLING AND TESTING - BITUMEN STABILISED MATERIAL 16
    se

    8.5.8 EVENNESS AND LEVEL 17


    8.6 DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN
    er

    (EXPANSION RATIO AND HALF LIFE) 18


    8.6.1 SCOPE 18
    ov

    8.6.2 DEFINITIONS 18
    8.6.3 APPARATUS 18
    o

    8.6.4 METHOD 19
    8.6.5 REPORTING 19
    it

    8.6.6 SITE QUALITY CONTROL 20


    et
    m

    APPENDIX ............................................................................................................................................ 21

    GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)
    QCS 2014 Section 06: Roadworks Page 2
    Part 08: Recycled and Stabilised Road Materials

    8 RECYCLED AND STABILISED ROAD MATERIALS


    8.1 GENERAL

    8.1.1 Scope

    1 This Part includes materials, equipment, mix design guidelines and other requirements for
    the construction of insitu and exsitu recycled pavement layers.

    2 Incorporation of stabilized or cement bound materials in pavement layers shall be based on


    pavement structural design criteria such as layer(s) strength characteristics, load distribution,
    layer(s) thickness equivalency, layers strength balance and the target level of pavement
    performance.

    .
    3 Use of recycled and stabilized materials and their associated construction and quality

    l
    .l.
    assurance and quality control processes shall be approved by the Engineer.

    rw
    4 Related Parts are:
    Section 6 Part 1 General
    Part 3 Earthworks
    ta
    qa
    Part 5 Asphalt Works
    Section 5
    Part 4 Water
    as

    8.1.2 References
    se

    AASHTO T180: ..........Standard Method of Test for Moisture-Density Relations of Soils


    ASTM C150: ..............Standard Specification for Portland Cement
    er

    ASTM C977: ..............Standard Specification for Quicklime and Hydrated Lime for Soil
    ov

    Stabilization
    ASTM C1097: ............Standard Specification for Hydrated Lime for Use in Asphalt Cement
    or Bituminous Pavements
    o

    ASTM D422: ..............Standard Test Method for Particle-Size Analysis of Soils


    it
    et

    ASTM D946: ..............Standard Specification for Penetration-Graded Asphalt Cement for


    Use in Pavement Construction
    m

    ASTM D1556: ............Standard Test Method for Density and Unit Weight of Soil in Place by
    Sand-Cone Method
    ASTM D1632: ............Standard Practice for Making and Curing Soil-Cement Compression
    and Flexure Test Specimens in the Laboratory
    ASTM D1633: ............Standard Test Methods for Compressive Strength of Molded Soil-
    Cement Cylinders
    ASTM D2216: ............Standard Test Methods for Laboratory Determination of Water
    (Moisture) Content of Soil and Rock by Mass
    ASTM D2922: ............Standard Test Methods for Density of Soil and Soil Aggregate in Place
    by Nuclear Methods (Shallow Depth)
    ASTM D4215: ............Standard Specification for Cold-Mixed, Cold-Laid Bituminous Paving
    Mixtures
    ASTM D4318: ............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
    Index of Soils
    QCS 2014 Section 06: Roadworks Page 3
    Part 08: Recycled and Stabilised Road Materials

    ASTM D4944: .............Standard Test Method for Field Determination of Water (Moisture)
    Content of Soil by the Calcium Carbide Gas Pressure Tester
    ASTM D4944: ............Standard Test Method for Field Determination of Water (Moisture)
    Content of Soil by the Calcium Carbide Gas Pressure Tester
    ASTM D6926: ............Standard Practice for Preparation of Bituminous Specimens Using
    Marshall Apparatus
    ASTM D6931: ............Standard Test Method for Indirect Tensile (IDT) Strength of
    Bituminous Mixtures
    ASTM D6938: ............Standard Test Method for In-Place Density and Water Content of Soil
    and Soil-Aggregate by Nuclear Methods (Shallow Depth)
    ASTM D7382: ............Standard Test Methods for Determination of Maximum Dry Unit
    Weight and Water Content Range for Effective Compaction of
    Granular Soils Using a Vibrating Hammer

    l .
    ASTM E2583: ............Standard Test Method for Measuring Deflections with a Light Weight

    .l.
    Deflectometer (LWD)

    rw
    MCHW Specification for Highways Works Series 900, UK
    TG2 Technical Guideline: Bitumen Stabilised Materials: Asphalt Academy, South Africa

    ta
    TRL 611: A Guide to the Use and Specification of Cold Recycled Materials
    qa
    8.1.3 Definitions

    1 Stabilisation is the permanent modification of soils and aggregates, including recycling


    as

    existing pavements, to enhance the engineering properties thereby improving the load
    bearing capacity and performance of a new pavement structure.
    se

    2 Aggregate: Granular material used in construction. Aggregate may be natural, manufactured


    er

    or recycled.
    ov

    3 Primary Aggregate: aggregate extracted directly from the ground in quarries or pits, or
    dredged from rivers or the sea. They can be either hard rock such as gabbro and limestone,
    o

    or sand and gravel.


    it

    4 Secondary Aggregate: materials produced as a by-product of other mining or quarrying


    et

    activities or as a by-product of other industrial processes, e.g. blast furnace slag, incinerator
    m

    ash, or the ash from power stations.

    5 Recycled Aggregate: materials produced by the recycling of construction and demolition


    waste. These can be crushed concrete, bricks or glass, asphalt planings (i.e. the asphalt
    layers of roads removed during roadworks, also known as RAP Recycled Asphalt
    Pavement).

    6 Cold Stabilised Material (CSM): materials produced for pavement construction structural
    layers using recycled or secondary aggregates.

    7 Bitumen Stabilised Material (BSM): granular aggregate materials bound with foamed
    bitumen or bitumen emulsions.

    8 Cement Treated Base (CTB): granular aggregate materials bound with cement or hydrated
    lime hydraulic binder.
    QCS 2014 Section 06: Roadworks Page 4
    Part 08: Recycled and Stabilised Road Materials

    9 Exsitu Stabilisation: mixing processes that are carried out away from the construction
    location in a remote mixing plant.

    10 Insitu Stabilisation: mixing processes that are carried out at the construction location by
    specialised stabilisation equipment.

    11 Optimum Moisture Content: the moisture content of soil at which a specific degree of
    compaction will produce the maximum dry density when determined in accordance with the
    AASHTO T180.

    12 Maximum Dry Density: the dry density of soil obtained using a specific degree of compaction
    at the optimum moisture content when determined in accordance with AASHTO T180.

    8.1.4 Submittals

    l .
    1 The Contractor shall submit recent test results for the proposed sources of materials for all

    .l.
    quality requirements of the Contract. The contractor shall submit a test certificate that proves

    rw
    that the raw materials that are purchased/used comply with specifications. The testing may
    be performed by an approved private laboratory or by the laboratory associated with the
    plant itself.

    2 ta
    The contractor shall submit to the Engineer for approval method statements, which includes
    qa
    but not limited to the following:
    (a) Quality assurance and quality control plans of all construction activities
    as

    (b) Material, handling, storage, identification and marking, traceability to source of


    se

    production and testing.


    (c) Equipment suitability to fulfil all construction activities to the required quality
    er

    (d) Personnel capability


    ov

    (e) Safety and environment preservation plans


    3 The Contractor will be required to produce detailed method statements for the chosen
    o

    method of recycling rehabilitation and shall include all stages of the process for approval by
    it

    the Engineer. This shall include the credentials and details of experience of the stabilising
    et

    contractor, the site investigation report, the stabilised material mix design and the equipment
    to be used for the entire process. A separate method statement shall be submitted for each
    m

    of the production and construction activities of each layer.

    8.1.5 Quality Assurance

    1 If requested the Contractor shall arrange for the Engineer to visit the source of the materials
    and jointly take samples for testing. The Contractor shall carry out testing as directed by the
    Engineer.

    8.2 COLD STABILISED MATERIAL - GENERAL

    1 Cold Stabilised Material (CSM) comprises base and binder courses produced by the process
    of in-place recycling (insitu) or in a fixed or mobile mixing plant (exsitu) where the aggregate
    source shall be obtained by cold pulverisation of all, or part, of the existing road structure,
    blended if necessary with other aggregate and bound with cementitious / hydraulic (CTB) or
    bituminous binders (BSM), separately or in combination, or by the use of primary
    aggregates.
    QCS 2014 Section 06: Roadworks Page 5
    Part 08: Recycled and Stabilised Road Materials

    2 Cold Stabilised Material (CSM) shall be designed and produced to form the foundation or
    main structural layer of the road pavement.

    3 For Bitumen Stabilised Material (BSM) the primary active binder (stabilising agent) shall be
    foamed bitumen, with cement as an adhesion agent as required by the design. For Cement
    Treated Base (CTB) the primary active binder shall be cement, hydrated lime or a blend of
    both in accordance with the mix design. The aggregate grading may be adjusted by the
    addition of inactive mineral filler.

    4 Insitu and exsitu methods of stabilisation rehabilitation are permissible with the approval of
    the Engineer on a site by site basis.

    5 Stabilisation design and installation processes shall be in accordance with internationally


    recognised standards and specifications, and shall meet the necessary pavement structural
    design according to the appropriate traffic classification.

    l .
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    6 The Cold Stabilised Material shall be designed to achieve the specified level of the

    rw
    appropriate end performance property to the requirements of the total pavement design. The
    minimum layer thickness shall be as required by the design method used, as approved by
    the Engineer.

    ta
    qa
    7 The asphalt type and thickness above the CSM shall be as required by the pavement design
    method and shall also be sufficient to prevent reflective cracking and early life trafficking, to
    the satisfaction of the Engineer.
    as

    8.3 MATERIALS
    se

    1 The method statement submitted by Contractor shall contain details of all aggregates to be
    er

    used in the CSM.


    ov

    2 Aggregates may include:


    (a) Material planed or excavated from a road or other paved area.
    o

    (b) Primary, secondary or recycled aggregate from other sources.


    it
    et

    (c) Mineral filler from primary or secondary sources.


    m

    3 The aggregate including added inactive filler shall not contain deleterious material that
    adversely affects the performance of the mixture. This includes clay materials, friable
    materials, organic and metallic materials, or other extraneous or detrimental material.

    4 The aggregate gradation for CSM shall follow the requirements stated in the mix design
    method, as approved by the Engineer, and shall generally follow the recommended
    gradations in Table 8.1 Recommended Gradations for Cold Stabilised Materials.

    5 For BSM, material passing the 0.425mm sieve shall have a maximum liquid limit of 25% and
    the plasticity index shall not exceed 6.

    6 Bitumen specified for use in BSM shall be 60/70 penetration grade in accordance with ASTM
    D946 and shall only be obtained from approved sources. The temperature of the bitumen
    prior to foaming shall be greater than 175C but less than 195C. Bitumen shall not contain
    any additives which may suppress foaming.
    QCS 2014 Section 06: Roadworks Page 6
    Part 08: Recycled and Stabilised Road Materials

    Table 8.1 Recommended Gradations for Cold Stabilised Materials


    Sieve Size Bitumen Stabilised Job Mix Control
    Cement Treat Base (CTB)
    (mm) Material (BSM) Sieve Tolerances
    50 100 100 100 100 -2
    37.5 85 100 87 100 5
    25 72 100 77 100 -
    19 60 100 67 99 8
    12.5 50 100 67 90 -
    9.5 42 90 48 80 8
    6.3 35 80 40 62 -
    4.75 30 72 35 56 10

    .
    2.36 21 56 25 42 -

    l
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    1.18 14 44 18 33 -

    rw
    0.6 9 35 14 28 5
    0.425 7 31 12 26 -
    0.3 5 27 10
    ta 24 -
    qa
    0.15 2 21 7 17 -
    0.075 2.0 18.0 4.0 10.0 3
    as
    se

    7 Cement specified for use in BSM and CTB shall be Portland cement in accordance with
    ASTM C150 and shall only be obtained from approved sources. Sulfate resisting cement
    er

    shall be used if instructed by the Engineer.


    ov

    8 Hydrated lime for use in BSM shall be in accordance with ASTM C1097 and for CTB shall be
    in accordance with ASTM C977, and shall only be obtained from approved sources.
    o

    9 Water for use in CSM shall in accordance with Section 5 Part 4.


    it
    et

    8.4 CEMENT TREATED BASE (CTB)


    m

    8.4.1 Preparation And Mix Design For Cement Treated Base

    1 The Contractor shall produce a detailed existing pavement investigation report and the
    proposed stabilised material mix design which shall be submitted for approval by the
    Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
    commencement of the stabilisation works. The pavement investigation report shall consist of
    cores and trial pits excavated to the existing subgrade and include tests for, but not limited
    to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
    liquid limit, and other tests required by the selected design method.

    2 All equipment and method statements shall be submitted for approval by the Engineer at
    least 30 days prior to commencement of works.
    QCS 2014 Section 06: Roadworks Page 7
    Part 08: Recycled and Stabilised Road Materials

    3 The mix design method for the CTB mix shall be as approved by the Engineer. Methods may
    include that stated in this part, MCHW Specification for Highways Works Series 900: UK, or
    other similar and equivalent recognised international design methods for cement or hydraulic
    bound materials.

    4 The CTB mix shall have a minimum individual 7 day compressive strength > 2.1 MPa with a
    maximum average 7 day compressive strength of 4.2 MPa when tested in accordance with
    ASTM D1633.

    5 The mix design shall derive the gradation tolerance parameters of the pulverised material,
    moisture content at the point of compaction and target flow rates for the active filler, binder
    and added water at the point of mixing, appropriate to the production or stabilisation method
    used for the approval of the Engineer.

    8.4.2 Site Trials For Cement Treated Base And Bitumen Stabilised Material

    l .
    .l.
    1 The CTB mix design shall be subjected to full preliminary trials and testing at least 10 days

    rw
    prior to commencement of the full works and shall determine:
    (a) The effectiveness of the production and laying plant for exsitu processes;
    (b)
    ta
    The number of passes of the stabilisation machine necessary to achieve uniform
    pulverisation and mixing for insitu processes;
    qa
    (c) The field moisture content control required to achieve specified compaction
    requirements;
    as

    (d) The compaction routine and rolling patterns necessary to meet the specified
    se

    compaction requirements;
    (e) The reference density;
    er

    (f) The effectiveness of the contractors inspection and test plan.


    ov

    2 The length of the trial section shall be at least 150 metres and the full width of the
    carriageway proposed for stabilisation to ensure joints and full width compaction can be
    o

    achieved without excessive segregation or other significant defects.


    it
    et

    3 The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2
    and allowed to cure for a minimum of 24 hours without trafficking unless otherwise
    m

    authorised by the Engineer.

    4 Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
    to commencement of the works. No works may proceed until all tests and final method
    statements have been submitted and approved by the Engineer.

    5 Where materials and processes are demonstrably similar, mix designs and trials tests from
    previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
    Quality Standards.

    8.4.3 Insitu Stabilisation And Compaction Of Cement Treated Base

    1 The insitu CTB stabilisation/recycling shall be produced by specialist equipment specifically


    designed for the purpose of insitu recycling processes.
    QCS 2014 Section 06: Roadworks Page 8
    Part 08: Recycled and Stabilised Road Materials

    2 The material shall be pulverised and stabilised in a single layer if its compacted thickness is
    300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
    pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
    thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
    the lower layer has achieved adequate stability before proceeding with the overlying layer.

    3 Where required by the Engineer the stability of a layer in any area shall be assessed after a
    curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
    truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
    The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
    of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
    mean vertical deformations at the above trafficking increments shall be plotted against the
    respective number of truck passes and the mean vertical deformation corresponding to 100
    standard axles shall be interpolated. The layer shall be deemed acceptable if the mean

    .
    vertical deformation corresponding to 100 standard axles is less than 10 mm.

    l
    .l.
    4 The active filler (cement/hydrated lime) shall be supplied to the recycler by a specifically

    rw
    designed and calibrated mobile slurry mixer to ensure the dustless addition of the
    cement/hydraulic binder. The addition shall be continuously monitored with records taken to

    ta
    confirm the target addition rate, 10%, according to the mix design.
    qa
    5 Mixing uniformity shall be continuously inspected visually by the contractor and work shall
    stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
    production process.
    as

    6 Should either the slurry mixer supply to the mixer fail to operate or deliver the correct
    se

    proportions to the recycler, all work shall cease until this has been corrected. Prior to
    resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
    er

    exceeding 50 metres to ensure the process is fully operational and under control.
    ov

    7 The recycler shall proceed in a continuous operation to the full depth of the layer being
    recycled as required by the pavement design.
    o

    8 The CTB moisture content prior to compaction shall be within 2 % of the target determined
    it

    during the mix design procedure to achieve maximum density.


    et
    m

    9 Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
    appropriate with the thickness of the layer being compacted. The vibration mode must be set
    on high amplitude to achieve maximum penetration of compactive effort.

    10 The rolling pattern should first concentrate on the middle section between the rear wheel
    paths of the recycler, then across the full cut width to achieve uniform density. The travel
    speed of the roller shall not exceed 3 km/h.

    11 When initial compaction is complete, the surface shall be struck off to level by a grader and
    the surface again checked for level and any defects or damage caused during the operation
    which shall be corrected prior to final compaction.

    12 Where the recycler has a screed finisher which achieves the required level, initial
    compaction shall follow the recommendations of the recycler supplier.
    QCS 2014 Section 06: Roadworks Page 9
    Part 08: Recycled and Stabilised Road Materials

    13 Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
    recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
    excessively over or under bindered, or watered.

    14 Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
    2
    rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking
    unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
    prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
    2
    applied at a rate of 5.5 to 7.0 kg/m .

    15 Traffic, including delivery vehicles shall not be permitted on the uncompacted or semi-
    compacted recycled material. The exposed longitudinal joint shall be protected from damage
    by construction plant and vehicles.

    8.4.4 Exsitu Production Of Cement Treated Base

    l .
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    1 The exsitu production of CTB shall be produced by specialist recycling and stabilisation

    rw
    production equipment specifically designed for the purpose of exsitu processes.

    2 The active filler (cement/hydrated lime) shall be supplied to the mixer by specifically

    ta
    designed and calibrated weighing apparatus to ensure the correct addition of the
    cement/hydraulic binder. The addition shall be continuously monitored with records taken to
    qa
    confirm the target addition rate, 10%, according to the mix design.
    as

    3 Mixing uniformity shall be continuously inspected visually by the contractor and work shall
    stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
    se

    production process.
    er

    4 CTB shall not segregate significantly during production and all measures shall be taken to
    avoid this occurrence.
    ov

    5 CTB shall be conveyed from the mixer to its place in the Works as rapidly as possible in
    covered vehicles which will prevent segregation or drying out and ensure that the material is
    o

    of the required workability and moisture content at the point of delivery to the paving
    it

    equipment.
    et

    6 Where CTB is produced on an exsitu production plant, the material shall be laid and fully
    m

    compacted within 2 hours of production, ensuring that the moisture content is within the
    required limits at the time of laying. CTB that exceeds 2 hours shall be rejected.

    8.4.5 Laying And Compaction Of Cement Treated Base

    1 Exsitu produced CTB materials shall be laid with paving machines and compaction plant as
    detailed in Section 6 Part 5, but may include additional specialist equipment deemed
    appropriate indicated in the detailed method statement.

    2 The CTB moisture content prior to compaction shall be within 2 % of the target determined
    during the mix design procedure to achieve maximum density.

    3 Material shall be laid to a thickness that would result in layers not more than 150 mm thick
    after compaction. Where the finished compacted thickness exceeds 150 mm placing shall
    be executed in composite layers each layer not exceeding 150 mm in compacted thickness
    as directed by the Engineer.
    QCS 2014 Section 06: Roadworks Page 10
    Part 08: Recycled and Stabilised Road Materials

    4 Final compaction for CTB shall follow the general requirements Section 6 Part 6 using a
    combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
    the approved method statement.

    5 Where the surface of the recycled layer has been graded to level, it may be dampened with
    a water spray prior to compaction. Care shall be taken not to use excessive watering.

    6 To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly
    moistened but excess water shall not be permitted.

    7 Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
    the requirements of Section 6 Part 5 shall be followed.

    8 After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
    and any irregularity of the surface exceeding the specified limits and any areas defective in

    l .
    texture, density or composition shall be corrected as directed by the Engineer, including

    .l.
    removal and replacement as directed by the Engineer.

    rw
    9 Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
    2
    rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking

    ta
    unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
    qa
    prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
    2
    applied at a rate of 5.5 to 7.0 kg/m .
    as

    8.4.6 Joints In Cement Treated Base


    se

    1 Transverse joints shall be made by cutting back at least 2 metres to the position of
    conforming level and compaction, and cleaned to remove any loose material. The joint shall
    er

    be fully compacted and left level and smooth.


    ov

    2 Longitudinal joints shall be formed as follows:

    3 For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of
    o

    the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to
    it

    cross compaction. Joints are deemed to be fresh when the pavement materials on both
    et

    sides of the joint have been stabilised and are able to be compacted within 1 hour. The
    500mm partially compacted strip together with the exposed edge shall be lightly moistened
    m

    prior to placement of the second strip.

    4 For paver laid materials and where the stabilised layer has been laid previously or is deemed
    unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to
    remove any loose material prior to paving the new adjacent strip.

    5 Longitudinal construction joints in CTB shall always be formed at the lane line marking
    positions where practically possible.

    8.4.7 Sampling And Testing - Cement Treated Base

    1 The Contractor shall produce an inspection and test plan for the complete process which
    shall include daily production control and the finished stabilised pavement for approval by the
    Engineer.

    2 Bulk samples shall be taken from the stabilised material to the full depth of the layer.
    QCS 2014 Section 06: Roadworks Page 11
    Part 08: Recycled and Stabilised Road Materials

    3 Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
    protected from the heat and sun in an ambient temperature of no greater than 20C.

    4 Samples shall be provided from the laid CTB before compaction, as approved by the
    Engineer. One group of five samples shall be provided from five locations equally spaced
    along a diagonal that bisects each 800m2 or part thereof laid each day. The number of
    groups may be increased if required by the Engineer. Each group shall be combined to
    provide samples for reference density, compressive strength and laboratory determined
    moisture content.

    5 For each group, 3 specimens for reference density and compressive strength testing shall be
    compacted in accordance with AASHTO T180within 2 hours of the addition of the cement
    and cured in accordance with ASTM D1632, and tested in accordance with ASTM D1633.

    6 To determine the reference density of test specimens the mould shall be weighed prior to
    making the specimen and the mass recorded. Immediately after completion of compaction,

    l .
    the specimen and mould shall be weighed and the mass recorded. These masses together

    .l.
    with the nominal volume of the mould shall be used to derive the reference density of the

    rw
    specimen.

    7 The in-situ density of a layer of cement bound material shall be taken as the average of the

    ta
    densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part
    thereof laid each day. The in-situ density at each location shall be the average of two
    qa
    readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
    shall be taken within two hours of completing final compaction.
    as

    8 Testing for CTB shall be required as Table 8. 2 Sampling and Testing Requirements for
    Cement Treated Base
    se
    er

    Table 8. 2 Sampling and Testing Requirements for Cement Treated Base


    ov

    TEST METHOD SAMPLE POINT SPECIFICATION FREQUENCY

    Sieve Pre-Stabilised Pulverised 3


    ASTM D422 Design mix gradation 1/1000m
    o

    Analysis Materials
    it

    Pre-Stabilised Pulverised Less than design mix 3


    Liquid Limit ASTM D4318 1/1000m
    et

    Materials determination
    Plasticity Pre-Stabilised Pulverised Less than design mix 3
    ASTM D4318 1/1000m
    m

    Index Materials determination


    ASTM Compacted Stabilised 2
    Field Density 100% reference density 5/800m
    D1556/D6938 Material
    Field
    Pre-compacted Stabilised 2
    Moisture ASTM D4944 2% OMC 1/800m
    Material
    Content
    Surface Compacted Stabilised 1 2
    ASTM E2583 Report Values 5/800m
    Modulus Material
    Compressive Pre-compacted Stabilised Individual >2.1 MPa 2
    ASTM D1633 1/800m
    Strength Material Average of 3 <4.2 MPa
    Reference Pre-compacted Stabilised 2
    AASHTO T-180 - 1/800m
    density Material
    Moisture 2
    ASTM D2216 Laid Stabilised Material 2% OMC 1/800m
    Content
    Note 1 The surface modulus determined in accordance with ASTM E2583 shall be reported as
    directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
    criteria.
    QCS 2014 Section 06: Roadworks Page 12
    Part 08: Recycled and Stabilised Road Materials

    8.4.8 Evenness And Level

    1 The transverse regularity of the surface of the CTB shall be tested by means of a 4 metre
    long straight edge. No irregularity in excess of 10 mm shall be permitted.

    2 The longitudinal regularity of the surface of the CTB shall be tested by means of a rolling
    straight edge. No irregularity in excess of 10 mm shall be permitted.

    3 The finished surface shall also be checked by dips or spot levels and shall be constructed to
    the designated grade levels to within 10 mm.

    4 Where these requirements are not met, the Contractor shall determine the full extent of the
    area which is out of tolerance and shall make good the surface of the course by scarifying to
    a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater,
    reshaping by adding or removing material as necessary, adding water if necessary and
    recompacting the layer. The minimum length of rectification shall be 50 metres.

    l .
    .l.
    5 Acceptance of the stabilised pavement is subject to completion of all testing and inspection
    requirements to the satisfaction of the Engineer.

    rw
    8.5 BITUMEN STABILISED MATERIAL (BSM)
    8.5.1
    ta
    Preparation And Mix Design For Bitumen Stabilised Material
    qa
    1 The Contractor shall produce a detailed existing pavement investigation report and the
    proposed stabilised material mix design which shall be submitted for approval by the
    Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
    as

    commencement of the stabilisation works. The pavement investigation report shall consist of
    cores and trial pits excavated to the existing subgrade and include tests for, but not limited
    se

    to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
    liquid limit, and other tests required by the selected design method.
    er

    2 All equipment and method statements shall be submitted for approval by the Engineer at
    ov

    least 30 days prior to commencement of works.

    3 The mix design method for the BSM mix shall be as approved by the Engineer. Methods
    o

    may include that stated in this part, or MCHW Specification for Highways Works Series 900:
    it

    (UK), or other similar and equivalent recognised international design methods for Bitumen
    et

    Stabilised Material.
    m

    4 The aggregate gradation for BSM shall follow the guideline in Error! Reference source not
    ound. unless otherwise stated in the approved alternative design method.

    5 The Design Mixture for BSM shall have minimum bitumen content of 2.5% with an active
    filler content no greater than 1%, by mass of total mix.

    6 The Binder Expansion Ratio (ER) shall be greater than 10 times and the Binder Half Life
    (T) greater than 12 seconds.

    7 The Indirect Tensile Strength dry (ITSdry - 100mm specimens) shall be greater than 225
    kPa and the Indirect Tensile Strength wet (ITSwet - 100mm specimens) shall be greater
    than 100 kPa when tested in accordance with ASTM D6931. The Tensile Strength Ratio
    (TSR) shall be greater than 80%

    8 The Unconfined Compressive Strength of the mixture shall be between 1200 and 3500 kPa
    when tested in accordance with ASTM D1633.
    QCS 2014 Section 06: Roadworks Page 13
    Part 08: Recycled and Stabilised Road Materials

    8.5.2 Site Trials For Bitumen Stabilised Material

    1 The BSM mix design shall be subjected to full preliminary trials and testing at least 10 days
    prior to commencement of the full works and shall determine:
    (a) the effectiveness of the production and laying plant for exsitu processes;
    (b) the number of passes of the stabilisation machine necessary to achieve uniform
    pulverisation and mixing for insitu processes;
    (c) the field moisture content control required to achieve specified compaction
    requirements;
    (d) the compaction routine and rolling patterns necessary to meet the specified
    compaction requirements;
    (e) the reference density;
    (f) the effectiveness of the contractors inspection and test plan.

    l .
    .l.
    2 The length of the trial section shall be at least 150 metres and the full width of the
    carriageway proposed for stabilisation to ensure joints and full width compaction can be

    rw
    achieved without excessive segregation or other significant defects.
    2
    3 The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m and

    ta
    allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by
    the Engineer.
    qa
    4 Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
    to commencement of the works. No works may proceed until all tests and final method
    as

    statements have been submitted and approved by the Engineer.


    se

    5 Where materials and processes are demonstrably similar, mix designs and trials tests from
    previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
    er

    Quality Standards.
    ov

    8.5.3 Insitu Stabilisation And Compaction Of Bitumen Stabilised Material

    1 The insitu BSM stabilisation/recycling shall be produced by specialist equipment specifically


    o

    designed for the purpose of insitu recycling processes.


    it

    2 The material shall be pulverised and stabilised in a single layer if its compacted thickness is
    et

    300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
    m

    pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
    thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
    the lower layer has achieved adequate stability before proceeding with the overlying layer.

    3 Where required by the Engineer the stability of a layer in any area shall be assessed after a
    curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
    truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
    The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
    of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
    mean vertical deformations at the above trafficking increments shall be plotted against the
    respective number of truck passes and the mean vertical deformation corresponding to 100
    standard axles shall be interpolated. The layer shall be deemed acceptable if the mean
    vertical deformation corresponding to 100 standard axles is less than 10 mm.

    4 The bitumen tanker shall a consistent flow of binder to the recycler. The addition shall be
    continuously monitored with records taken to confirm the target addition rate, 10%,
    according to the mix design.
    QCS 2014 Section 06: Roadworks Page 14
    Part 08: Recycled and Stabilised Road Materials

    5 The active filler (cement) shall be supplied to the recycler by a specifically designed and
    calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder.
    The addition shall be monitored with records taken to confirm the correct addition rate
    according to the mix design.

    6 Mixing uniformity shall be continuously inspected visually by the contractor and work shall
    stop when bitumen streaks or blotches are observed, or where cement is seen to
    agglomerate or not fully mix in during the production process.

    7 Should either the slurry mixer or the binder supply to the mixer fail to operate or deliver the
    correct proportions to the recycler, all work shall cease until this has been corrected. Prior to
    resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
    exceeding 50 metres to ensure the process is fully operational and under control.

    8 The recycler shall proceed in a continuous operation to the full depth of the layer being
    recycled as required by the pavement design.

    l .
    .l.
    9 The BSM moisture content prior to compaction shall be within 2 % of the target determined
    during the mix design procedure to achieve maximum density.

    rw
    10 Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
    appropriate with the thickness of the layer being compacted. The vibration mode must be set

    ta
    on high amplitude to achieve maximum penetration of compactive effort.
    qa
    11 The rolling pattern should first concentrate on the middle section between the rear wheel
    paths of the recycler, then across the full cut width to achieve uniform density. The travel
    speed of the roller shall not exceed 3 km/h.
    as

    12 When initial compaction is complete, the surface shall be struck off to level by a grader and
    se

    the surface again checked for level and any defects or damage caused during the operation
    which shall be corrected prior to final compaction.
    er

    13 Where the recycler has a screed finisher which achieves the required level, initial
    ov

    compaction shall follow the recommendations of the recycler supplier.

    14 Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
    o

    recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
    it

    excessively over or under bindered, or watered.


    et

    15 Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
    m

    rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking
    unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
    prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
    applied at a rate of 5.5 to 7.0 kg/m2.

    16 Traffic, including delivery vehicles shall not be permitted on the uncompacted or semi-
    compacted recycled material. The exposed longitudinal joint shall be protected from damage
    by construction plant and vehicles.

    8.5.4 Exsitu Production Of Bitumen Stabilised Material

    1 The exsitu production of BSM shall be produced by specialist recycling and stabilisation
    production equipment specifically designed for the purpose of exsitu processes.

    2 The bitumen shall be supplied to the mixer by specifically designed and calibrated metering
    apparatus to ensure the correct addition of the binder. The addition shall be continuously
    monitored with records taken to confirm the target addition rate, 10%, according to the mix
    design.
    QCS 2014 Section 06: Roadworks Page 15
    Part 08: Recycled and Stabilised Road Materials

    3 The active filler (cement) shall be supplied to the mixer by specifically designed and
    calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder.
    The addition shall be continuously monitored with records taken to confirm the target
    addition rate, 10%, according to the mix design.

    4 Mixing uniformity shall be continuously inspected visually by the contractor and work shall
    stop when bitumen streaks or blotches are observed or where cement is seen to
    agglomerate or not fully mix in during the production process.

    5 BSM shall not segregate significantly during production and all measures shall be taken to
    avoid this occurrence.

    6 BSM shall be conveyed from the mixer to its place in the Works as rapidly as possible in
    covered vehicles which will prevent segregation or drying out and ensure that the material is
    of the required workability and moisture content at the point of delivery to the paving
    equipment.

    l .
    .l.
    7 Where BSM is produced on an exsitu production plant, the material shall be laid and fully
    compacted within 2 hours of production, ensuring that the moisture content is within the

    rw
    required limits at the time of laying. BSM that exceeds 2 hours shall be rejected.

    8.5.5 Laying And Compaction Of Bitumen Stabilised Material

    1 ta
    Exsitu produced BSM materials shall be laid with paving machines and compaction plant as
    qa
    detailed in Section 6 Part 5, but may include additional specialist equipment deemed
    appropriate indicated in the detailed method statement.
    as

    2 The BSM moisture content prior to compaction shall be within 2 % of the target determined
    during the mix design procedure to achieve maximum density.
    se

    3 Material shall be laid to a thickness that would result in layers not more than 150 mm thick
    er

    after compaction. Where the finished compacted thickness exceeds 150 mm placing shall
    be executed in composite layers each layer not exceeding 150 mm in compacted thickness
    ov

    as directed by the Engineer.

    4 Final compaction for BSM shall follow the general requirements Section 6 Part 5 using a
    o

    combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
    it

    the approved method statement.


    et

    5 Where the surface of the recycled layer has been graded to level, it may be dampened with
    m

    a water spray prior to compaction. Care shall be taken not to use excessive watering.

    6 To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly
    moistened but excess water shall not be permitted.

    7 Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
    the requirements of Section 6 Part 5 shall be followed.

    8 After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
    and any irregularity of the surface exceeding the specified limits and any areas defective in
    texture, density or composition shall be corrected as directed by the Engineer, including
    removal and replacement as directed by the Engineer.

    9 Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
    2
    rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking
    unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
    prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
    2
    applied at a rate of 5.5 to 7.0 kg/m .
    QCS 2014 Section 06: Roadworks Page 16
    Part 08: Recycled and Stabilised Road Materials

    8.5.6 Joints In Bitumen Stabilised Material

    1 Transverse joints shall be made by cutting back at least 2 metres to the position of
    conforming level and compaction, and cleaned to remove any loose material. The joint shall
    be fully compacted and left level and smooth.

    2 Longitudinal joints shall be formed as follows:


    (a) For paver laid materials, fresh joints may be formed by compacting 500mm at the
    edge of the initial stabilised strip with a single roller pass and abutting the adjacent
    new strip prior to cross compaction. Joints are deemed to be fresh when the pavement
    materials on both sides of the joint have been stabilised and are able to be compacted
    within 1 hour. The 500mm partially compacted strip together with the exposed edge
    shall be lightly moistened prior to placement of the second strip.
    (b) For paver laid materials and where the stabilised layer has been laid previously or is
    deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and

    .
    cleaned to remove any loose material prior to paving the new adjacent strip.

    l
    .l.
    3 Longitudinal construction joints in BSM shall always be formed at the lane line marking

    rw
    positions where practically possible.

    8.5.7 Sampling And Testing - Bitumen Stabilised Material

    1 ta
    The Contractor shall produce an inspection and test plan for the complete process which
    qa
    shall include daily production control and the finished stabilised pavement for approval by the
    Engineer.
    as

    2 Bulk samples shall be taken from the stabilised material to the full depth of the layer.
    se

    3 Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
    protected from the heat and sun in an ambient temperature of no greater than 20C.
    er

    4 Samples shall be provided from the laid BSM before compaction, as approved by the
    ov

    Engineer. One group of five samples shall be provided from five locations equally spaced
    2
    along a diagonal that bisects each 800m or part thereof laid each day. The number of
    groups may be increased if required by the Engineer.
    it o

    5 For each group, 3 specimens for strength based testing shall be compacted within 2 hours of
    the addition of the bitumen binder. Reference density and UCS shall be compacted and
    et

    cured in accordance with AASHTO T-180, and tested in accordance with ASTM D1633. ITS
    m

    testing shall be compacted in accordance with ASTM D6926 and tested in accordance with
    ASTM D6931.

    6 The foamed bitumen expansion ratio and half life shall be determined at the commencement
    of works each day if required by the Engineer.

    7 To determine the reference density of test specimens the mould shall be weighed prior to
    making the specimen and the mass recorded. Immediately after completion of compaction,
    the specimen and mould shall be weighed and the mass recorded. These masses together
    with the nominal volume of the mould shall be used to derive the reference density of the
    specimen.

    8 The in-situ density of a layer of cement bound material shall be taken as the average of the
    2
    densities at five locations equally spaced along a diagonal that bisects each 800 m or part
    thereof laid each day. The in-situ density at each location shall be the average of two
    readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
    shall be taken within two hours of completing final compaction.
    QCS 2014 Section 06: Roadworks Page 17
    Part 08: Recycled and Stabilised Road Materials

    9 Testing for BSM shall be required as Table 8.3 Sampling and Testing Requirements for
    BSM.

    Table 8.3 Sampling and Testing Requirements for BSM


    SPECIFICATION
    TEST METHOD SAMPLE POINT FREQUENCY
    LIMIT

    Pre-Stabilised Design mix 3


    Sieve Analysis ASTM D422 1/1000m
    Pulverised Materials gradation

    Pre-Stabilised 3
    Liquid Limit ASTM D4318 Maximum 25 1/1000m
    Pulverised Materials

    Pre-Stabilised 3
    Plasticity Index ASTM D4318 Maximum 6 1/1000m
    Pulverised Materials

    ASTM Compacted Stabilised 100% reference

    .
    2
    Field Density 5/800m

    l
    D1556/D6938 Material density

    .l.
    Field Moisture Pre-compacted 2

    rw
    ASTM D4944 2% OMC 1/800m
    Content Stabilised Material

    Surface Compacted Stabilised Report Test 2


    ASTM E2583 5/800m

    ta
    1
    Modulus Material Values
    qa
    Binder Pre-mixing/ 1/first 500
    This Part:8.6 >10 times 2
    Expansion Ratio stabilisation m /day
    as

    Binder Half Life Pre-mixing/ 1/first 500


    This Part:8.6 > 12 seconds 2
    () stabilisation m /day
    se

    Unconfined
    ASTM D1633 Pre-compacted 2
    Compressive 1200 to 3500 kPa 1/800m
    (150mm) Stabilised Material
    Strength
    er

    Moisture Laid Stabilised 2


    ASTM D2216 2% OMC 1/800m
    Content Material
    ov

    Indirect Tensile ASTM D6931 Pre-compacted ITSdry >225 kPa 1/day if


    2
    Strength (100mm) Stabilised Material ITSwet >100 kPa >800m
    it o

    Tensile Strength Pre-compacted 1/day if


    ITSwet / ITSdry > 80% 2
    et

    Retained (TSR) Stabilised Material >800m

    Note 1 The surface modulus determined in accordance with ASTM E2583 shall be reported as
    m

    directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
    criteria.

    8.5.8 Evenness And Level

    1 The transverse regularity of the surface of the BSM shall be tested by means of a 4 metre
    long straight edge. No irregularity in excess of 10 mm shall be permitted.

    2 The longitudinal regularity of the surface of the BSM shall be tested by means of a rolling
    straight edge. No irregularity in excess of 10 mm shall be permitted.

    3 The finished surface shall also be checked by dips or spot levels and shall be constructed to
    the designated grade levels to within 10 mm.
    QCS 2014 Section 06: Roadworks Page 18
    Part 08: Recycled and Stabilised Road Materials

    4 Where these requirements are not met, the Contractor shall determine the full extent of the
    area which is out of tolerance and shall make good the surface of the course by scarifying to
    a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater,
    reshaping by adding or removing material as necessary, adding water if necessary and
    recompacting the layer. The minimum length of rectification shall be 50 metres.

    5 Acceptance of the stabilised pavement is subject to completion of all testing and inspection
    requirements to the satisfaction of the Engineer.

    8.6 DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN


    (EXPANSION RATIO AND HALF LIFE)

    8.6.1 Scope

    .
    1 The foaming characteristics of bitumen are defined by the Expansion Ratio and Half Life of

    l
    .l.
    the bitumen in its expanded state. The expanded state of the bitumen is achieved when a
    small percentage of water is introduced into hot bitumen. The objective is to determine the

    rw
    percentage of water required that will produce the best foam characteristics for a particular
    source of bitumen. The aim is to produce foamed bitumen with the largest expansion ratio
    with the longest half-life possible.
    ta
    qa
    8.6.2 Definitions

    1 The expansion ratio is a measure of the viscosity of the foam and provides an indication of
    as

    how well the binder will disperse in the mix. It is calculated as the ratio of the maximum
    volume of foam relative to the original volume of bitumen. The half-life is a measure of the
    se

    stability of the foam and provides an indication of the rate of collapse of the foam during
    mixing. It is calculated as the time taken in seconds for the foam to collapse to half of its
    er

    maximum volume.
    ov

    8.6.3 Apparatus

    1 The following equipment shall be required:


    it o

    (a) For mix design only: Foamed Bitumen Laboratory Unit, capable of producing foamed
    bitumen at a rate of between 50g and 200g per second. The method of production
    et

    shall closely simulate that of full scale production of foamed bitumen on the recycling
    m

    machine. The apparatus shall have a thermostatically controlled kettle capable of


    holding a mass of 10kg of bitumen at a constant temperature between the range of
    160C and 200C, 5C. The unit shall have an expansion chamber similar to that on
    the recycling machine in which cold water is injected into hot bitumen. Water injection
    shall be variable from 0 to 5% (by mass of the bitumen) with an accuracy of 0.25%.
    The plant shall capable of accurately discharging a predetermined mass of foamed
    bitumen directly into the mixing bowl of an electrically driven laboratory mixer with a
    minimum capacity of 10kg.
    (b) Cylindrical metal container, 250mm diameter and at least 20 litre capacity.
    (c) Calibrated Dip Stick, calibrated for the cylindrical metal container with 500g of bitumen
    as 1 unit measure. Prongs are attached to the dip stick at every 5 or 6 times the unit
    volume.
    (d) A stop-watch with 60 second dial.
    (e) Heat resistant gloves.
    (f) An electronic balance to weigh up to 10kg, accurate to 1g.
    QCS 2014 Section 06: Roadworks Page 19
    Part 08: Recycled and Stabilised Road Materials

    8.6.4 Method

    1 Preparation
    (a) The foamed bitumen laboratory unit discharge rates are checked in accordance with
    the manufactures specifications. If the unit is being used for the first time then the
    pump rate and water flow rates need to be calibrated as per the manufactures
    specifications. Check that 500g of bitumen is being discharged at the predetermined
    settings.
    (b) Ensure that the cylindrical metal container and dip stick are reasonably clean.
    Discharge foamed bitumen, at least twice, into cylindrical metal container prior to
    testing in order to pre-heat the container. Decant excess bitumen from the container
    into a suitable waste receptacle.

    2 Testing

    l .
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    (a) Heat the bitumen in the kettle of the foamed bitumen laboratory unit with the pump
    circulating the bitumen through the system until the required temperature is achieved

    rw
    (normally starting with 160 C). Maintain the required temperature for at least 5
    minutes prior to commencing with testing.
    (b)
    ta
    Set the water flow-meter to achieve the required water injection rate (normally starting
    qa
    with 2 % by mass of the bitumen).
    (c) Discharge foamed bitumen into the preheated steel drum for the calculated spray time
    for 500 g of bitumen. Immediately after the foamed bitumen discharge stops, start a
    as

    stopwatch.
    se

    (d) Using the calibrated dipstick measure the maximum height the foamed bitumen
    achieves in the drum. This maximum volume is recorded as the expansion. Continue
    er

    to measure the time in seconds that the foam takes to dissipate to half of its maximum
    volume. This is recorded as the foamed bitumens half-life.
    ov

    (e) Repeat the above procedures three times or until similar readings are achieved.
    (f) The expansion and half-life are determined at different percentages of water.
    o

    Typically, values of 2 %, 3 % and 4 % by mass of bitumen are used.


    it
    et

    (g) Plot a graph of the expansion ratio versus half-life at the different water injection rates
    on the same set of axes. The optimum water addition is chosen as an average of the
    m

    two water contents required to meet the minimum criteria. (Figure 7.1 Determination of
    Optimum Foaming Water)
    (h) If the required properties are not met at 160C, further testing should be carried out
    with the bitumen at higher temperatures (typically 170C and 180C).

    8.6.5 Reporting

    1 The foamed bitumen characteristics and optimum water content are reported as;
    Optimum water content (%): Percentage by mass of bitumen;
    Expansion (times): Ratio of maximum expansion to original volume of bitumen;
    Half-life (sec): Time taken from maximum expansion to half this volume.
    QCS 2014 Section 06: Roadworks Page 20
    Part 08: Recycled and Stabilised Road Materials

    8.6.6 Site Quality Control


    The above method may be used to determine the expansion ratio and half-life of foamed
    bitumen dispensed by the production plant or recycler.

    l .
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    rw
    ta
    Figure 7.1 Determination of Optimum Foaming Water
    qa
    as
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 06: Roadworks Page 21
    Part 08: Recycled and Stabilised Road Materials

    l .
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    APPENDIX

    rw
    ta
    qa
    GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED
    MATERIALS (MIX DESIGNS)
    as
    se
    er
    ov
    ito
    et
    m
    QCS 2014 Section 06: Roadworks Page 22
    Part 08: Recycled and Stabilised Road Materials

    8.7 GENERAL 23
    8.7.1 PREPARATION OF SAMPLES FOR MIX DESIGN PROCEDURES 23
    8.7.2 MIX DESIGN PROCEDURE FOR CEMENT STABILISED MATERIALS 25
    8.7.3 MIX DESIGN PROCEDURE FOR BITUMEN STABILISED MATERIALS (BSMS) 27
    8.7.4 DETERMINATION OF THE FLUID / DENSITY RELATIONSHIP 28
    8.7.5 PREPARATION FOR STABILISING W ITH BITUMEN EMULSION (BSM-EMULSION) 29
    8.7.6 PREPARATION FOR STABILISING W ITH FOAMED BITUMEN (BSM-FOAM) 29
    8.7.7 MANUFACTURE OF 100MM DIAMETER SPECIMENS 32
    8.7.8 DETERMINATION OF THE STRENGTH OF 100MM DIAMETER SPECIMENS 34
    8.7.9 MANUFACTURE OF 150MM DIAMETER SPECIMENS 34
    8.7.10 DETERMINATION OF THE STRENGTH OF 150MM DIAMETER SPECIMENS 36
    8.7.11 STRENGTH TEST PROCEDURES 37
    8.7.12 SELECTION OF THE AMOUNT OF BITUMEN TO BE ADDED FOR BSM 38

    .
    8.7.13 DETERMINATION OF THE SHEAR PROPERTIES OF BSM 40

    l
    .l.
    8.7.14 DETERMINATION OF TRIAXIAL SHEAR PARAMETERS USING SIMPLE TRIAXIAL TEST 40
    8.7.15 USING LABORATORY TEST RESULTS FOR ESTIMATING STRUCTURAL LAYER COEFFICIENTS 45

    rw
    8.7.16 PROFORMA REPORT SHEET FOR ITS TESTING 46
    8.7.17 LABORATORY EQUIPMENT REQUIREMENTS 47

    ta
    qa
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    et
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    QCS 2014 Section 06: Roadworks Page 23
    Part 08: Recycled and Stabilised Road Materials

    8.7 GENERAL
    The detailed procedures for carrying out stabilisation mix designs in a laboratory are
    described below. Procedures for both cement (or lime) and bitumen stabilisation are
    included as well as guidelines for interpreting the test results for bitumen stabilised materials
    (BSMs). Comprehensive lists of laboratory equipment are provided. In addition, a chart has
    been included showing how laboratory test results can be utilised to indicate the relevant
    structural coefficient for a BSM (for use in the AASHTO 1993 pavement design method).

    8.7.1 Preparation Of Samples For Mix Design Procedures

    1 Field Sampling: Bulk samples are obtained from test pits excavated as part of the field
    investigations. Each layer in the upper pavement ( 300mm) must be sampled separately
    and at least 150kg of material recovered from each layer that is likely to be included in any

    .
    mix design procedure. Representative samples shall be obtained and prepared either from

    l
    .l.
    the excavation process at source or by laboratory crushing and screening.

    rw
    2 Standard soil tests: Carry out the following standard tests on the material sampled from each
    individual layer:
    (a)
    ta
    Sieve analysis to determine the grading (ASTM D 422);
    qa
    (b) Atterberg limits to determine the liquid limit and plasticity index (ASTM D 4318); and
    (c) Moisture / density relationship (AASHTO T-180).
    as

    3 Sample blending: Where necessary, blend the materials sampled from the different layers to
    obtain a combined sample representing the material from the full recycling depth. The in-situ
    se

    density of the various components must be considered when blending materials, as


    illustrated in
    er
    ov

    4 Figure 7.1 Determination of Optimum Foaming Water Repeat the standard soil tests
    described above to determine the grading and plasticity index of the blended sample.
    it o

    Existing upper
    pavement structure
    et
    m

    60mm Asphalt
    3
    (in situ density 2300 kg/m )
    60mm Asphalt
    Recycling depth 200mm
    +
    200mm Subbase =
    3
    140mm Gravel
    (in situ density 2000 kg/m )

    The materials are blended in proportion to layer thickness and insitu density as follows:
    Per square metre Proportion by mass Per 10kg sample
    Material
    (kg) (%) (g)
    0.06 x 2300 =
    Asphalt (60mm at 2300 kg/m3) 138/418 = 0.33 0.33 x 10000 = 3300
    138
    0.14 x 2000 =
    Gravel (140mm at 2000 kg/m3) 280/418 = 0.67 0.67 x 10000 = 6700
    280
    Total 418 1.00 10000
    Figure 7.2 Example of Density Proportioning
    QCS 2014 Section 06: Roadworks Page 24
    Part 08: Recycled and Stabilised Road Materials

    5 Representative proportioning: Separate the material in the representative sample into the
    following four fractions:
    Retained on the 19.0mm sieve;
    Passing the 19.0mm sieve, but retained the 12.5 mm sieve;
    Passing the 12.5 mm sieve, but retained on the 4.75mm sieve; and
    Passing the 4.75mm sieve.
    Reconstitute representative samples in accordance with the grading up to the portion
    passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material
    that passes the 19.0mm sieve, but is retained on the 12.5 mm sieve. The example in Table
    8.4 Material Combination explains this procedure:

    .
    Table 8.4 Material Combination

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    .l.
    Sieve analysis Quantity of material to be included in a 10kg sample

    rw
    Sieve
    Percentage passing Passing 12.5mm Passing 19mm
    size Passing 4.75mm
    (from sieve analysis) Retained 4.75mm Retained 12.5mm
    (mm)

    19 90.5
    ta
    ((72.3-53.6)/100 x
    qa
    (53.6/100 x 10000) ((100-72.3)/100 x 10000)
    12.5 72.3 = 5360g
    10000)
    = 2770g
    = 1870g
    4.75 53.6
    as

    If there is insufficient material (i.e. passing the 19mm sieve but retained on the 12.5mm
    se

    sieve) for substituting that retained on the 19mm sieve, then lightly crush the material
    retained on the 19.0mm sieve to provide more of this fraction.
    er

    6 Sample quantities: The guidelines shown Table 8.5 Test Quantities should be used for the
    ov

    quantity of material required for the respective tests:


    o

    Table 8.5 Test Quantities


    it
    et

    Test Sample quantity required

    Moisture / density relationship (AASHTO T180) 5 x 7kg


    m

    Unconfined Compressive Strength (150mm specimens) 20kg per stabiliser content


    Bitumen stabilisation mix design (100mm specimens) Minimum 10kg per stabiliser content
    Bitumen stabilisation mix design (150mm specimens ) Minimum 20kg per stabiliser content
    Determination of moisture content Approximately 1kg

    7 Hygroscopic moisture content: Two representative air-dried samples, each approximately


    1kg, are used to determine the hygroscopic (air dried) moisture content of the material.
    (Note: Larger sample size should be used for more coarsely-graded materials.) Weigh the
    air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a
    temperature of between 105C and 110C until they achieve constant mass. The
    hygroscopic moisture content (W air-dry) is the loss of mass expressed as a percentage of the
    dry mass of the sample. Determine the hygroscopic moisture using equation 1:
    QCS 2014 Section 06: Roadworks Page 25
    Part 08: Recycled and Stabilised Road Materials

    W air-dry = (Mmoist Mdry) / Mdry x 100 [Equation 1]

    where: W air-dry = hygroscopic moisture content [% by mass]


    Mmoist = mass of moist material [g]
    Mdry = mass of dry material [g]

    8.7.2 Mix Design Procedure For Cement Stabilised Materials

    1 Determination of the Moisture / Density Relationship: This test is carried out using standard
    compaction effort to determine the Optimum Moisture Content (OMC) and Maximum Dry
    Density (MDD) of the cement stabilised material.
    Step 1: Weigh out the required mass of stabilising agent for each of five 7kg samples
    prepared as described in 8.7.1. The amount of stabilising agent required (expressed as a
    percentage by mass of the dry sample) should be close to the anticipated optimum for the

    l .
    material being treated. In the absence of previous tests, the following can be used as a

    .l.
    guideline:

    rw
    Subbase layers: 2% for coarse material (> 50% retained on 4.75mm sieve)
    3% for fine material (< 50% retained on 4.75mm sieve)

    Base layers: ta
    4% for coarse material (> 50% retained on 4.75mm sieve)
    qa
    6% for fine material (< 50% retained on 4.75mm sieve)
    Step 2: Add the stabilising agent to the raw material and mix immediately prior to the
    as

    addition of water. In order to simulate conditions on the road, compaction of the stabilised
    material is delayed for one hour after mixing the untreated material with stabilising agent and
    se

    water. The mixed material is placed in an air-tight container to prevent loss of moisture and
    is thoroughly mixed every fifteen minutes.
    er

    Step 3: Determine the OMC and MDD for the stabilised material in accordance with the
    ov

    modified moisture-density relationship test procedure (AASHTO T-180).

    2 Manufacture of Specimens for Strength Testing: The procedure described below is for the
    o

    manufacture specimens that are of 150mm in diameter and 127mm in height. These
    it

    specimens will be used to determine the Unconfined Compressive Strength (UCS) and
    et

    Indirect Tensile Strength (ITS) of the material.


    m

    Step 1: Place the 20kg sample, prepared as described in 8.7.1, into a suitable mixing
    container.
    Step 2: Determine the dry mass of the sample using equation 2:
    Msample = (Mair-dry/ (1 + (W air-dry x 100)) [Equation 2]

    where: Msample = dry mass of sample [g]


    Mair-dry = air-dried mass of the sample [g]
    W air-dry = moisture content of air-dried sample [% by mass]
    Step 3: Determine the required amount of stabilising agent using equation 3:
    Mcement = (Cadd / 100) x Msample [Equation 3]

    where: Mcement = mass of lime or cement to be added [g]


    Cadd = percentage of lime or cement required [% by mass]
    Msample = dry mass of the sample [g]
    QCS 2014 Section 06: Roadworks Page 26
    Part 08: Recycled and Stabilised Road Materials

    Step 4: Determine the percentage water to be added for optimum mixing purposes using
    equation 4 and then the mass of water to be added to the sample using equation 5:
    W add = W OMC - W air-dry [Equation 4]

    Mwater = (W add / 100) x (Msample + Mcement) [Equation 5]

    where: W add = water to be added to sample [% by mass]


    W OMC = optimum moisture content [% by mass]
    W air-dry = moisture content of air-dried sample [% by mass]
    Mwater = mass of water to be added [g]
    Msample = dry mass of the sample [g]
    Mcement = mass of lime or cement to be added [g]

    .
    Step 5: Mix the material, cement and water until uniform. Allow the mixed material to stand

    l
    .l.
    for one hour with occasional mixing, as described above, before compacting three 150mm
    diameter specimens using modified AASHTO (T-180) compaction effort. (Note: Two 150mm

    rw
    diameter specimens are normally manufactured for each test.)
    Step 6: Samples are taken during the compaction process and dried to a constant mass (at

    ta
    105 to 110C) to determine the moulding moisture content (W mould). Determine the moulding
    moisture using equation 6:
    qa
    W mould = (Mmoist - Mdry) / Mdry x 100)) [Equation 6]
    as

    where: W mould = moulding moisture content [% by mass]


    Mmoist = mass of moist material [g]
    se

    Mdry = mass of dry material [g]


    Steps 7 to 9: Repeat the above steps for at least three different stabiliser contents.
    er

    Step 10: Remove the specimens from the moulds either by dismantling the split moulds or, if
    ov

    ordinary moulds are used, extruding the specimens carefully with an extrusion jack, avoiding
    distortion to the compacted specimens.
    o

    Step 11: Record the mass and volume of each specimen and determine the dry density
    it

    using equation 7:
    et

    DD = (Mbriq / Vol) x (100 / W mould +100) x 1000 [Equation 7]


    m

    where: DD = dry density [kg/m]


    Mbriq = mass of specimen [g]
    3
    Vol = volume of specimen [cm ]
    W mould = moulding moisture content [%]

    Note: With certain materials lacking cohesion, it may be necessary to leave the specimens in the
    moulds for 24 hours to develop strength before extracting. When this is necessary, the
    specimens in the moulds should be kept in a curing room or covered with damp cloth (hessian).

    3 Curing the Specimens: Cure the specimens for seven days at 95% to 100% relative humidity
    and at a temperature of 20C to 25C in a suitable curing room.
    An alternative curing method is to place the specimen in sealed plastic bags and cure in an
    oven at:
    70C to 75C for 24 hours for cement; or
    QCS 2014 Section 06: Roadworks Page 27
    Part 08: Recycled and Stabilised Road Materials

    60C to 62 C for 45 hours for lime.


    After the curing period, remove the specimens from the curing room (or plastic bags) and
    allow to cool to ambient temperature, if necessary. Specimens for unconfined compressive
    strength (UCS) tests should be submerged in water at 22C to 25C for four hours prior to
    testing.

    4 Strength Tests: The Unconfined Compressive Strength (UCS) test and the Indirect Tensile
    Strength (ITS) test procedures are described under 8.7.11.

    5 Determination of the Optimum Stabiliser Content: The ITS and UCS strengths achieved are
    plotted against the percentage stabilising agent added using the average UCS or ITS of the
    three specimens for each stabiliser content, ignoring any obvious incorrect result that may
    have been caused by damage to the specimen before testing. The required application rate
    of stabilising agent is that percentage at which the minimum required criteria are met.

    l .
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    8.7.3 Mix Design Procedure For Bitumen Stabilised Materials (Bsms)

    rw
    1 Active Filler Requirements: Bitumen stabilisation is normally carried out in combination with a
    small amount (1% by mass) of active filler (cement or hydrated lime) to enhance the

    ta
    dispersion of the bitumen and/or the breaking time (where bitumen emulsion is used as the
    stabilisation agent). The PI of the material is used as an initial guideline for the use of
    qa
    hydrated lime or cement in the mix:
    as

    Table 8.6 Guide to Addition of Active Filler


    Plasticity Index: < 10 Plasticity Index: > 10
    se

    Pre-treat with hydrated lime (ICL value)


    Carry out Preliminary Level 1 tests
    er

    (The initial consumption of lime (ICL value)


    (explained below) to determine the need to
    must first be determined using the
    add cement or hydrated lime.
    ov

    appropriate pH test.)

    Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2
    o

    hours prior to the addition of the bitumen emulsion or foamed bitumen. (The treated material
    it

    must be placed in an air-tight container to retain moisture and the moisture content checked
    et

    and, if necessary, adjusted prior to adding the bitumen stabilising agent.) Such materials are
    not subjected to Preliminary Level 1 tests.
    m

    2 Preliminary Level 1 Tests: Where the PI < 10, the need for an active filler and the type of
    active filler (cement or hydrated lime) that is appropriate for the material must first be
    determined by carrying out Level 1 tests on three different mixes. The same amount of
    bitumen (residual bitumen for bitumen emulsion treatment) is added to all three mixes,
    determined from the fractions passing the 4.75mm and 0.075mm sieves, as shown in Table
    8.7 Suggested bitumen addition relative to key aggregate fractions.
    QCS 2014 Section 06: Roadworks Page 28
    Part 08: Recycled and Stabilised Road Materials

    Table 8.7 Suggested bitumen addition relative to key aggregate fractions


    Percentage passing sieve size (%) Bitumen addition
    (% of dry aggregate)
    4.75mm 0.075mm
    < 5.0 2.0
    5.0 7.5 2.25
    < 50
    7.5 10.0 2.5
    > 10.0 2.75
    < 5.0 2.25
    5.0 7.5 2.5
    > 50
    7.5 10.0 3.0

    l .
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    > 10.0 3.5
    The first mix contains no active filler, 1% cement is added to the second mix and 1%

    rw
    hydrated lime is added to the third mix. 100mm diameter specimens are manufactured,
    cured and tested to determine the relevant ITSDRY, ITSWET and TSR values as described
    in 8.7.12.
    ta
    Where the TSR value for the mix with no active filler added is in excess of 60%, the mix
    qa
    design should be undertaken with no active filler. (This situation is usually confined to
    materials consisting of good quality crushed stone, often including a high proportion of
    as

    reclaimed asphalt pavement (RAP) material.)


    Where the TSR value of the mix with no active filler added is less than 60%, the mix with the
    se

    type of active filler that produces a significantly higher TSR value (> 5%) indicates whether
    cement or hydrated lime should be used. If the TSR values for both active fillers are of the
    er

    same order (difference < 5%) then either type of active filler is suitable.
    Note. Should cement and/or hydrated lime be not readily available and tests indicate the
    ov

    need for an active, the use of 15% (by volume) quarry fine aggregate (5mm to 0mm) or
    similar material with > 10% passing the 0.075mm sieve may be used as a substitute in the
    o

    mix designs.
    it
    et

    8.7.4 Determination Of The Fluid / Density Relationship


    The Optimum Fluid Content (OFC) and the Maximum Dry Density (MDD) of the stabilised
    m

    material is determined using standard compaction effort.


    Note: For foamed bitumen stabilisation, the OFC and MDD can be assumed to be the same
    as the OMC and MDD, as determined for representative samples of the untreated material.
    The OFC for bitumen emulsion treated material is the percentage by mass of bitumen
    emulsion plus additional moisture required to achieve the maximum dry density in the treated
    material. As described below, the OFC is determined by adding a constant percentage of
    bitumen emulsion whilst varying the amount of water added.
    Step 1: Measure out the bitumen emulsion as a percentage by mass of the air-dried material
    for each of five prepared samples following the procedure described in 8.7.1. The
    percentage of bitumen emulsion added is normally between 2 and 3% residual bitumen (e.g.
    for 3% residual bitumen, add 5% of a 60% bitumen emulsion).
    Step 2: The bitumen emulsion and water is added to the material and mixed until uniform
    immediately prior to compaction.
    Step 3: Determine the OFC and MDD for the stabilised material in accordance with the
    modified moisture-density relationship test procedure (AASHTO T-180).
    QCS 2014 Section 06: Roadworks Page 29
    Part 08: Recycled and Stabilised Road Materials

    8.7.5 Preparation For Stabilising With Bitumen Emulsion (Bsm-Emulsion)


    Step 1: Place the required quantity of sample into a suitable mixing container (10kg for the
    manufacture of 100mm diameter specimens, or 20kg for the manufacture of 150mm
    diameter specimens).
    Step 2: Determine the dry mass of the sample using equation 1.
    Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
    Step 4: Determine the required percentage (by mass) of bitumen emulsion using equation 8:
    Memul = (RBreqd / PBE) x Msample [Equation 8]

    where: Memu = mass of bitumen emulsion to be added [g]


    RBreqd = percentage of residual bitumen required [% by mass]
    PBE = percentage of bitumen in emulsion [% by mass]

    .
    Msample = dry mass of the sample [g]

    l
    .l.
    Step 5: Determine the amount of water to be added for optimum compaction purposes using
    equation 9:

    rw
    Mwater = {((W OFC W air-dry) / 100) x Msample} Memul [Equation 9]

    where: Mwater
    W OFC
    = mass of water to be added
    = optimum fluid content ta [g]
    [% by mass]
    qa
    W air-dry = moisture content of air-dried sample [% by mass]
    Memul = mass of bitumen emulsion to be added [g]
    as

    Msample = dry mass of the sample [g]


    se

    Step 6: Mix the material, active filler, bitumen emulsion and water together until uniform.
    Immediately manufacture specimens following the relevant procedure for either 100mm or
    150mm diameter specimens, as described in 8.7.7 and 8.7.9 respectively.
    er

    Repeat above steps for at least four mixes with different bitumen emulsion contents.
    ov

    Recommended bitumen addition interval for different specimen sizes


    Difference in amount of bitumen added (%) to
    o

    Specimen diameter (mm)


    each mix
    it

    100 (Level 1) 0.25


    et

    150 (Level 2) 0.1


    m

    For 100mm diameter specimens, use Error! Reference source not found. as a guideline
    or the amount of bitumen addition that the material will require for effective stabilisation.
    For 150mm diameter specimens, use the results of Level 1 tests from 8.7.8 as the maximum
    addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
    value).

    8.7.6 Preparation For Stabilising With Foamed Bitumen (Bsm-Foam)

    1 Determination of the foaming properties of the bitumen: The foaming properties of each
    bitumen type is characterised by:
    Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio
    of the maximum volume of the foam relative to the original volume of bitumen; and
    Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in
    seconds for the foam to collapse to half of its maximum volume.
    QCS 2014 Section 06: Roadworks Page 30
    Part 08: Recycled and Stabilised Road Materials

    The objective is to determine the temperature and percentage of water addition that is
    required to produce the best foam properties (maximum expansion ratio and half-life) for a
    particular source of bitumen. This is achieved at three different bitumen temperatures (not
    exceeding 195C) with the following procedure:
    Step 1: Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump
    circulating the bitumen through the system until the required temperature is achieved
    (normally starting with160C). Maintain the required temperature for at least 5 minutes prior
    to commencing with testing.
    Step 2: Calibrate the discharge rate of the bitumen and set the timer on the Wirtgen WLB10
    S to discharge 500g of bitumen (Qbitumen).
    Step 3: Set the water flow-meter to achieve the required water injection rate (normally
    starting with 2% by mass of the bitumen).
    Step 4: Discharge foamed bitumen into a preheated ( 75C) steel drum for a calculated

    .
    spray time for 500g of bitumen. Immediately after the foam discharge stops, start a

    l
    .l.
    stopwatch.
    Step 5: Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel

    rw
    drum of 275mm in diameter and 500g of bitumen) measure the maximum height the foamed
    bitumen achieves in the drum. This is recorded as the maximum volume.

    ta
    Step 6: Use the stopwatch to measure the time in seconds that the foam takes to dissipate
    to half of its maximum volume. This is recorded as the foamed bitumens half-life.
    qa
    Step 7: Repeat the above procedure three times or until similar readings are achieved.
    Step 8: Repeat steps 3 to 7 for a range of at least three water injection rates. Typically,
    as

    values of 2%, 3% and 4% by mass of bitumen are used.


    Step 9: Plot a graph of the expansion ratio versus half-life at the different water injection
    se

    rates on the same set of axes (see the example in graph below). The optimum water
    addition is chosen as an average of the two water contents required to meet these minimum
    er

    criteria.
    ov

    Repeat Step 1 to 9 for two other bitumen temperatures (normally 170C and 180C).
    The temperature and optimum water addition that produces the best foam is then used in the
    o

    mix design procedure described below.


    it

    Note: The absolute minimum foaming properties that are acceptable for effective
    et

    stabilisation (material temperature of 25C) are:


    Expansion ratio: 10 times
    m

    Half-life: 12 seconds

    2 If the minimum requirements cannot be met, the bitumen should be rejected as unsuitable
    for use.
    QCS 2014 Section 06: Roadworks Page 31
    Part 08: Recycled and Stabilised Road Materials

    3 Prepare the material for foamed bitumen treatment as follows:


    Step 1: Place 20 to 25kg of sample prepared as described in 8.7.1 into the Wirtgen WLM30
    pugmill mixer.
    Step 2: Determine the dry mass of the sample using equation 2.
    Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
    Step 4: Determine the percentage water to be added for optimum mixing moisture content
    as calculated using equation 10. The amount of water to be added to the sample is
    determined using equation 11.
    W add = 0.75W OMC - W air-dry [Equation 10]

    Mwater = (W add / 100) x (Msample + Mcement) [Equation 11]

    where: W add = water to be added to sample [% by mass]

    l .
    .l.
    W OMC = optimum moisture content [% by mass]

    rw
    W air-dry = moisture content of air-dried sample [% by mass]
    Mwater = mass of water to be added [g]
    Msample = dry mass of the sample
    ta
    Mcement = mass of lime or cement to be added
    [g]
    [g]
    qa
    Step 5: Mix the material, active filler and water in the mixer until uniform.
    Note: Inspect the sample after mixing to ensure that the mixed material is not packed
    as

    against the sides of the mixer. If this situation occurs, mix a new sample at a lower moisture
    content. Check to see that the material mixes easily and remains in a fluffed state. If any
    se

    dust is observed at the end of the mixing process, add small amounts of water and remix
    until a "fluffed" state is achieved with no dust.
    er

    Step 6: Determine the amount of foamed bitumen to be added using equation 12:
    ov

    Mbitumen = (Badd /100) x (Msample + Mcement) [Equation 12]

    where: Mbitumen = mass of foamed bitumen to be added [g]


    o

    Badd = foamed bitumen content [% by mass]


    it

    Msample = dry mass of the sample [g]


    et

    Mcement = mass of lime or cement to be added [g]


    m

    Step 7: Determine the timer setting on the Wirtgen WLB10 S using equation 13:
    T = Mbitumen / Qbitumen [Equation 13]

    where: T = time to be set on WLB10 S timer [s]


    Mbitumen = mass of foamed bitumen to be added [g]
    Qbitumen = bitumen flow rate for the WLB10 S [g/s]
    Step 8: Position the mixer adjacent to the foaming unit so that the foamed bitumen can be
    discharged directly into the mixing chamber.
    Step 9: Start the mixer and allow it to mix for at least 10 seconds before discharging the
    required mass of foamed bitumen into the mixing chamber. After the foamed bitumen has
    discharged into the mixer, continue mixing for a further 30 seconds or until uniformly mixed.
    Step 10: Determine the amount of water required to bring the sample to the OMC using
    equation 14.
    QCS 2014 Section 06: Roadworks Page 32
    Part 08: Recycled and Stabilised Road Materials

    = (W OMC W sample) / 100 x (Msample +


    Mplus [Equation 14]
    Mcement)
    where: Mplus = mass of water to be added [g]
    W OMC = optimum moisture content [% by mass]
    W sample = moisture content of prepared sample [% by mass]
    Msample = dry mass of the sample [g]
    Mcement = mass of lime or cement added [g]
    Note: This moisture adjustment is to be carried out when 150mm diameter specimens are
    to be manufactured. Where 100mm diameter specimens are to be manufactured, the
    moisture content of the material is to be adjusted to 90% of OMC.
    Step 11: Add the additional water and mix until uniform.
    Step 12: Transfer the foamed bitumen treated material into a container and immediately

    .
    seal the container to retain moisture. To minimise moisture loss from the prepared sample,

    l
    .l.
    manufacture the specimens as soon as possible following the relevant procedure for either
    100mm or 150mm diameter specimens, as described in 8.7.7 and 8.7.9 respectively.

    rw
    Repeat the above steps for at least four mixes with different foamed bitumen contents.

    ta
    Recommended bitumen addition interval for different specimen sizes
    qa
    Difference in amount of bitumen added (%)
    Specimen diameter (mm)
    to each mix
    as

    100 (Level 1) 0.25

    150 (Level 2) 0.1


    se

    For 100mm diameter specimens, use Error! Reference source not found. as a guideline
    er

    or the amount of bitumen addition that the material will require for effective stabilisation.
    For 150mm diameter specimens, use the results of Level 1 tests in 8.7.8 as the maximum
    ov

    addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
    value).
    it o

    8.7.7 Manufacture Of 100mm Diameter Specimens


    et

    1 For Level 1 mix designs ITS tests are carried out on 100mm diameter specimens. Six
    m

    specimens are manufactured for each sample at the different bitumen contents. The two
    primary objectives of undertaking the Level 1 mix design are to determine:
    the optimum bitumen content for the BSM, and
    the need for an active filler.

    2 Specimens may be made using either Marshall or vibratory compaction methods.

    3 Marshall Compaction shall be carried out as follows:


    Step 1: Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate
    and face of the compaction hammer.
    Note: the compaction equipment must not be heated but kept at ambient temperature.
    Step 2: Weigh sufficient material to achieve a compacted height of 63.5mm 1.5mm
    (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
    and 10 times on the surface, leaving the surface slightly rounded.
    QCS 2014 Section 06: Roadworks Page 33
    Part 08: Recycled and Stabilised Road Materials

    Step 3: Compact the mixture by applying 75 blows with the compaction hammer. Care must
    be taken to ensure the continuous free fall of the hammer. Remove the mould and collar
    from the pedestal, invert the specimen (turn over). Replace it and press down firmly to
    ensure that it is secure on the base plate. Compact the other face of the specimen with a
    further 75 blows.
    Step 4: Take approximately 1kg representative samples after compaction of the second and
    fifth specimen and dry a constant mass (at 105 to 110C). Determine the moulding moisture
    using equation 15:
    W mould = (Mmoist Mdry) / Mdry x 100 [Equation 15]

    where: W mould = moulding moisture content [% by mass]


    Mmoist = mass of moist material [g]
    Mdry = mass of dry material [g]

    .
    Step 5: After compaction, remove the mould from the base-plate and extrude the specimen

    l
    .l.
    by means of an extrusion jack. Measure the height of the specimen and adjust the amount
    material if the height is not within the required limits.

    rw
    Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
    the mould for 24 hours, allowing sufficient strength to develop before extracting.

    4 Vibratory Compaction shall be carried out as follows:ta


    qa
    Step 1: Fix the mounting head and appropriate tamping foot to the vibratory hammer and fit
    hammer onto guide rods. Place 5kg surcharge weight onto mounting head (total mass of
    as

    assembly [Hammer + foot + surcharge] = 25kg) and fasten tightly. Using the pulley system
    raise the vibratory hammer to an adequate height that will allow operator to work safely
    se

    beneath the vibratory hammer and lock in position.


    Step 2: Clean the mould, collar and base plate. Fix the mould to the base of the compaction
    er

    frame.
    ov

    Note: the compaction equipment must not be heated but kept at ambient temperature.
    Step 3: Weigh sufficient material to achieve a compacted height of 63.5mm 1.5mm
    (usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
    o

    and 10 times on the surface, leaving the surface slightly rounded.


    it

    Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is
    et

    perpendicular to the base of the mould. Apply 15 seconds of vibratory compaction to the
    m

    sample in the mould.


    Step 5: Raise hammer to the safe position, remove mould, invert mould and secure to base.
    Step 6: Lower vibratory hammer to surface of material in mould and ensure vibratory
    hammer rests freely on sample and is perpendicular to the base of the mould. Apply further
    15 seconds of vibratory compaction to sample in the mould.
    Step 7: Take approximately1kg representative samples after compaction of the second and
    fifth specimen and dry to constant mass (at 105 to 110 oC). Determine the moulding
    moisture using equation 15.
    Step 8: After compaction, remove the mould from the base-plate and extrude the specimen
    carefully by means of an extrusion jack.
    Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
    the mould for 24 hours, allowing sufficient strength to develop before extracting.
    QCS 2014 Section 06: Roadworks Page 34
    Part 08: Recycled and Stabilised Road Materials

    5 Curing procedure: Compacted specimens shall be cured by placing the specimens on a steel
    mesh and curing in a forced-draft oven until a constant mass is obtained (normally 72 hours
    at 40C). Remove from oven after curing and allow to cool to ambient temperature.

    6 When specimens have cooled to ambient temperature determine the bulk density for each
    specimen:
    Step 1. Determine the mass (Mbriq).
    Step 2. Measure the height at four evenly-spaced places around the circumference and
    calculate the average height (h).
    Step 3. Measure the diameter (d).
    Step 4. Calculate the bulk density using equation 16:
    2
    BD = (4 x Mbriq x h) x 1000 [Equation 16]

    .
    where: BD = moulding moisture content [kg/m]

    l
    .l.
    Mbriq = mass of specimen [g]

    rw
    h = average height of specimen [cm]
    d = diameter of specimen [cm]

    ta
    Note: Exclude from further testing any specimen whose bulk density differs from the mean
    bulk density of the batch by more than 50 kg/m.
    qa
    7 The bulk density may alternatively be determined by using the weigh-in air / weigh-in water
    method for those specimens designated for soaked testing.
    as

    8.7.8 Determination Of The Strength Of 100mm Diameter Specimens


    se

    1 The 100mm diameter specimens are tested for indirect tensile strength under dry and
    er

    soaked conditions to determine the ITSDRY and the ITSWET values. To prevent moisture loss,
    specimens should be tested as soon as they are prepared. The results are used to indicate
    ov

    the optimum bitumen content and the need for active filler. In addition, these test results are
    used as a guide for the classification of the BSM.
    o

    8.7.9 Manufacture Of 150mm Diameter Specimens


    it
    et

    1 Level 2 mix designs ITS tests are carried out on specimens that are 150mm diameter and
    m

    95mm in height. These specimens are cured to simulate the equilibrium moisture content
    achieved in the field. This method of curing provides more realistic values for classification of
    the bitumen stabilised materials.

    2 The procedures described allow for the manufacture of four 150mm diameter specimens to a
    compacted height of 95mm. If additional specimens are required, the sample quantity shall
    be increased.

    3 Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
    methods.

    4 MODIFIED AASHTO (T-180) compaction shall be carried out as follows:


    Step 1: Prepare and treat at least 24kg of sample for each selected bitumen content.
    Step 2: Where required, add sufficient moisture to bring sample to optimum compaction
    moisture content and mix until uniform. Immediately after mixing, place material in an air-
    tight container.
    QCS 2014 Section 06: Roadworks Page 35
    Part 08: Recycled and Stabilised Road Materials

    Step 3: Take approximately 1kg representative samples after compaction of the first and
    third specimen and dry to a constant mass (at 105 to 110C). Determine the moulding
    moisture using equation 15.
    Step 4: Compact at least 4 specimens using a 150mm diameter split-mould, applying
    modified AASHTO (T-180) compaction effort (4 layers approximately 25mm thick, 56 blows
    per layer using a 4.536kg hammer with a 457mm drop).
    Step 5: Carefully trim excess material from specimens, as specified in the AASHTO T180
    test method.
    Step 6: Carefully remove the specimen from the spilt-mould and place on a steel mesh.
    Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
    the mould for 24 hours, allowing sufficient strength to develop before extracting.

    5 Vibratory compaction shall be carried out as follows:

    .
    Step 1: Fix the mounting head and appropriate tamping foot (150mm diameter) to the

    l
    .l.
    vibratory hammer and fit hammer onto guide rods. Place 10kg surcharge weight onto

    rw
    mounting head (total mass of assembly [hammer + foot + surcharge] = 30kg) and fasten
    tightly. Using the pulley system raise the vibratory to an adequate height that will allow
    operator to work safely beneath the vibratory hammer and lock in position.

    ta
    Step 2: Clean the 150mm diameter spilt mould, collar and base plate. Fix the mould to the
    qa
    base of the compaction frame.
    Step 3: Weigh sufficient material to achieve a compacted height of 47.5mm 1.5mm. An
    approximation of the quantity required can be calculated using equation 17. Spade the
    as

    mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving
    the surface slightly rounded.
    se

    2
    Mmix = ( x d x h / 4) x (MDD) /1000 [Equation 17]
    er

    where: Mmix = Mass of mixed material [g]


    ov

    d = diameter of specimen [cm]


    h = required height of layer (4.75cm for ITS) [cm]
    o

    MDD = maximum dry density [kg/m]


    it

    Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is
    et

    perpendicular to the base of the mould.


    Apply 25 seconds of vibration for bitumen emulsion stabilised materials
    m

    35 seconds of vibration for foamed bitumen stabilised materials.


    Step 5: Raise hammer to safe position.
    Step 6: For the second layer, if necessary, adjust for the amount of material to be added
    such that the final compacted thickness is 95mm. Using a chisel, scarify the entire surface
    area of the top of the compacted layer to a maximum depth of 10mm. Add the required
    amount of material and ensure the material is as level as possible.
    Step 7: Lower the vibratory hammer into the mould, checking that the vibratory hammer is
    perpendicular to the base of the mould.
    Apply 25 seconds of vibration for bitumen emulsion stabilised materials
    35 seconds of vibration for foamed bitumen stabilised materials.
    Step 8: Raise hammer to safe position. Remove mould from base plate and open the split
    mould to remove the specimen.
    QCS 2014 Section 06: Roadworks Page 36
    Part 08: Recycled and Stabilised Road Materials

    Step 9: Take approximately 1kg representative samples after compaction of the first and
    third specimens and dry to a constant mass. Determine the moulding moisture using
    equation 15.
    Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
    the mould for 24 hours, allowing sufficient strength to develop before extracting.

    6 Curing procedure: Place the specimens in an oven at 40C for 24 hours (or until the moisture
    content has reduced to at least 50% of OMC). Thereafter place each specimen in a sealed
    plastic bag (at least twice the volume of the specimen) and place in an oven at 40C for a
    further 48 hours.

    7 Remove specimens from the oven after 48 hours and remove the respective plastic bags,
    ensuring that any moisture in the bags does not come into contact with the specimen. Allow
    to cool to ambient temperature.

    l .
    .l.
    8 When specimens have cooled to ambient temperature determine the bulk density for each
    specimen:

    rw
    Step 1: Determine the mass (Mbriq).
    Step 2: Measure the height at four evenly-spaced places around the circumference and
    calculate the average height (h).
    ta
    qa
    Step 3: Measure the diameter (d).
    Step 4: Calculate the bulk density using equation 16:
    as

    Note: Exclude from further testing any specimen whose bulk density differs from the mean
    bulk density of the batch by more than 50 kg/m.
    se

    9 The bulk density may alternatively be determined by using the weigh-in air / weigh-in water
    er

    method for those specimens designated for soaked testing.


    ov

    8.7.10 Determination Of The Strength Of 150mm Diameter Specimens

    1 The 150mm diameter specimens are tested for indirect tensile strength under equilibrium
    o

    moisture content and soaked conditions to determine the ITSEQUIL and the ITSSOAK values. To
    it

    prevent moisture loss, specimens should be tested as soon as they are prepared. The
    et

    results are used to refine the optimum bitumen content and amount of active filler that was
    initially determined from the 100mm diameter specimens. In addition, these test results are
    m

    used to classify the BSM with additional confidence.

    2 Additional ITS tests should be carried out using 150mm diameter specimens to determine
    the sensitivity of the mix to minor variations in both the amount of added bitumen and active
    filler.
    If, for example, Level 2 test results indicated an optimum bitumen addition (OBA) of 2.2%
    with an active filler addition of 1%, then the following further tests should be undertaken:
    Step 1: To check the sensitivity of the bitumen addition, follow the Level 2 procedure in 8.7.9
    to manufacture, cure and test the following mixes:
    QCS 2014 Section 06: Roadworks Page 37
    Part 08: Recycled and Stabilised Road Materials

    Added bitumen (%) Active filler (%)


    2.2 (Level 2 OBA) 1
    2.1 1
    2.0 1
    1.9 1
    ITS test results will allow the optimal bitumen addition (OBA) to be refined.
    Step 2: To check the sensitivity of the amount of active filler added, follow the Level 2
    procedure in 8.7.9 to manufacture, cure and test the following mixes:
    Added bitumen (%) Active filler (%)
    OBA 0.9
    OBA 0.7
    OBA 0.5

    .
    ITS test results will indicate the minimum amount of active filler required in the mix.

    l
    .l.
    8.7.11 Strength Test Procedures

    rw
    1 The Unconfined Compressive Strength (UCS) of a cement stabilised material is determined
    by measuring the ultimate load to failure of a 127mm high and 150mm diameter specimen

    ta
    that is subjected to a constant loading rate of 140kPa/s (153kN/min), as follows:
    qa
    Step 1: Place the specimen on its flat side between the plates of the compression testing
    machine. Position the specimen such that it is centred on the loading plates.
    as

    Step 2: Apply the load to the specimen, without shock, at a rate of advance of 140kPa/s until
    the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.
    se

    Step 3: Immediately after testing a specimen, break the specimen up and take a sample of
    approximately 1000g to determine the moisture content (W break). This moisture content is
    er

    used to determine the dry density of the material using equation 21.
    Step 4: Calculate the UCS for each specimen to the nearest 1 kPa according to equation 18.
    ov

    = (4 x P) / ( x d ) x 10000
    2
    UCS [Equation 18]
    o

    where: UCS = unconfined compressive strength [kPa]


    it

    P = maximum load to failure [kN]


    et

    d = diameter of specimen [cm]


    m

    2 Indirect Tensile Strength (ITS) of a stabilised material is determined by measuring the


    ultimate load to failure of a specimen (both 100mm and 150mm diameter specimens) that is
    subjected to a constant deformation rate of 50.8 mm/minute on its diametrical axis, as
    follows:
    Step 1: Place the specimen onto the respective ITS jig for the 100mm and 150mm diameter
    specimens. Position the sample such that the loading strips are parallel and centred on the
    vertical diametrical plane.
    Step 2: Place the load transfer plate on the top bearing strip and position the jig assembly
    centrally under the loading ram of the compression testing device.
    Step 3: Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per
    minute until the maximum load is reached. Record the maximum load P in kN, accurate to
    0.1kN.
    QCS 2014 Section 06: Roadworks Page 38
    Part 08: Recycled and Stabilised Road Materials

    Step 4: Immediately after testing a specimen, break it up and take a sample of


    approximately 1000g to determine the moisture content (W break). This moisture content is
    used in equation 21 to determine the dry density of the material in the specimen.
    Step 5: Immediately after testing a specimen, measure the temperature of the broken face
    using a digital thermometer. Record the temperature, accurate to 0.1C.
    Step 6: Calculate the ITS for each specimen to the nearest 1 kPa using equation 19:
    ITS = (2 x P) / ( x h x d) x 10000 [Equation 19]

    where: ITS = indirect tensile strength [kPa]


    P = maximum applied load [kN]
    h = average height of the specimen [cm]
    d = diameter of specimen [cm]
    Step 7: To determine the soaked ITS, place the specimens under water at 25C 1C for 24

    l .
    hours. Remove specimen from water, surface dry and repeat steps 1 to 5.

    .l.
    Record the results and determine the following as required:

    rw
    100mm specimens: ITSDRY = average of 3 specimens cured to constant mass
    ITSWET = average of 3 ITSDRY specimens soaked for 24 hours.
    150mm specimens: ITSEQUIL = average of 2 specimens cured at equilibrium moisture

    ta
    ITSSOAK = average of 2 ITSEQUIL specimens soaked for 24 hours
    qa
    Step 8: Determine the Tensile Strength Retained (TSR). The TSR is the relationship
    between the average soaked and unsoaked ITS values for a specific batch of specimens,
    expressed as a percentage using equation 20:
    as

    TSR = Average soaked ITS / Average unsoaked ITS x 100 [Equation 20]
    se

    Step 9: Using the moisture content determined in each test described above, calculate the
    dry density using equation 21:
    er

    DD = (Mbriq / Vol) x (100 / (W break + 100) x 1000 [Equation 21]


    ov

    where: DD = dry density [kg/m]


    Mbriq = mass of cured specimen [g]
    o

    3
    Vol = volume of specimen [cm ]
    it

    W break = moisture content of the specimen [%]


    et

    Report the results using the template sheet shown in 8.7.16 as a guide.
    m

    8.7.12 Selection Of The Amount Of Bitumen To Be Added For Bsm

    1 Plot the results of the respective soaked and unsoaked ITS test results against the relevant
    bitumen content that was added. The added bitumen content that best meets the desired
    BSM classification is selected as the optimum amount of bitumen to be added, as shown in
    the example below (Figure 7.3 Determination of BSM class and added bitumenFigure 7.3
    Determination of BSM class and added)
    QCS 2014 Section 06: Roadworks Page 39
    Part 08: Recycled and Stabilised Road Materials

    Interpretation of ITS Tests

    Test Specimen BSM1 BSM2 BSM3 Purpose

    Indicates the optimum bitumen


    ITSDRY 100 mm > 225 175 to 225 125 to 175
    content

    ITSWET 100 mm > 100 75 to 100 50 to 75 Indicates need for active filler.

    Indicates problem material where


    TSR 100 mm N/A N/A N/A
    TSR < 50 and ITSDRY > 400 kPa
    Used for classifying the BSM and
    ITSEQUIL 150 mm > 175 135 to 175 95 to 135 for optimising the bitumen and
    active filler content.

    .
    ITSSOAK 150 mm > 150 100 to 150 60 to 100 Check value on ITSWET

    l
    .l.
    rw
    ta
    qa
    as
    se
    er
    ov
    it o
    et

    Figure 7.3 Determination of BSM class and added bitumen


    m

    2 The TSR value is useful for identifying problem materials. If the TSR is less than 50%, it is
    recommended that active filler is used. If such treatment does not increase the ITSWET value
    with a maximum application of 1% lime or cement, then the nature of the material being
    stabilised should be investigated:

    3 Where the material is granular, a TSR value below 50% combined with an ITSDRY value in
    excess of 400 kPa suggests contamination (normally attributed to clay or deleterious
    materials). In this situation, it is suggested that material is pre-treated with hydrated lime and
    the Level 1 tests repeated.

    4 Where the material is 100% RAP, a TSR value below 50% combined with an ITSDRY value in
    excess of 500 kPa indicates that the treated material is partly stabilised and partly
    continuously bound (cold mix). In this situation, the material probably requires blending with
    crusher dust to ensure that the stabilisation process dominates the mix.
    QCS 2014 Section 06: Roadworks Page 40
    Part 08: Recycled and Stabilised Road Materials

    5 Level 2 testing using 150mm diameter specimens should be undertaken to verify the
    relevant ITS values for BSM classification.

    8.7.13 Determination Of The Shear Properties Of Bsm

    1 Triaxial testing is carried out to determine the cohesion and angle of internal friction of BSM
    specimens. Testing is normally carried out at the bitumen content selected from the results
    of ITS tests carried out on 150mm diameter specimens (see above). Additional tests at
    different bitumen contents can always be carried out to investigate the sensitivity of the
    shear properties.

    2 Specimens for triaxial testing shall be produced as follows:


    Step 1: Prepare and treat 50kg of sample (adequate for manufacture of 4 specimens) with
    either bitumen emulsion or foamed bitumen at the optimum bitumen content. Include any

    .
    active filler requirements.

    l
    .l.
    Step 2: Where required, add moisture to bring sample to optimum compaction moisture

    rw
    content and mix until uniform. Place the mixed material in an air-tight container.
    Step 3: Take approximately1 kg representative samples of each specimen to determine the
    moulding moisture using equation 15.

    ta
    Step 4: Compact at least four (4) specimens using a 150mm diameter split mould with an
    qa
    effective internal height of 300mm, using equation 17 to calculate the approximate quantity
    for each layer.
    as

    3 Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
    methods.
    se

    4 Compaction using modified AASHTO (T180) shall be in 12 layers, each approximately 25mm
    er

    thick, compacted with 56 blows using a 4.536kg hammer with a 457mm drop. Carefully trim
    any excess material from the specimen.
    ov

    5 Compaction using vibratory compaction shall be in 5 layers, each approximately 60mm thick,
    o

    using a hammer assembly of 30kg total mass. Each layer is compacted for:
    it

    25 seconds for BSM-emulsion, or


    et

    35 seconds for BSM-foam


    m

    The height of each compacted layer is measured and, if necessary, an adjustment made for
    the quantity of material used for the next layer to achieve the required height for the
    respective layers.

    6 The specimens shall be cured using the same procedure for 150mm diameter specimens.

    8.7.14 Determination Of Triaxial Shear Parameters Using Simple Triaxial Test

    1 This method describes the determination of triaxial shear parameters (cohesion and internal
    angle of friction) of Bitumen Stabilised Materials by measuring the resistance to failure
    (monotonic) of a cylindrical 150 mm diameter and 300 2 mm height specimen prepared
    according to Vibratory Hammer Compaction Procedure.
    QCS 2014 Section 06: Roadworks Page 41
    Part 08: Recycled and Stabilised Road Materials

    2 Apparatus:
    (a) Triaxial Cell comprising a galvanised steel casing 5 mm thick comprising a ring handle
    and simple mechanical clamps top and bottom, a base with bottom platen for sitting
    specimen, top disk and a latex tube at least 320 mm in height.
    (b) Testing System comprising a Material Testing System (MTS) or its equivalent system
    must at least comprise of an actuator, reaction frame, a control panel and data
    acquisition system. The system must be capable of providing ramp loads with
    minimum loading capacity of 100 kN and a minimum stroke of 40 mm. The actuator
    should be operated by a servo-controlled hydraulic pressure system with a closed loop
    feedback system that is capable of both displacement and load controlled testing if
    required.
    (c) Measuring devices should include but not limited to a load cell (100 kN Capacity) for
    measuring load, an actuator displacement transducer (> 40 mm stroke) for measuring

    l .
    displacement (deformation) and pressure regulator, gauges, and valves for lateral

    .l.
    pressure.

    rw
    (d) Additionally air compressor, loading ram and silicon oil or grease.

    3 The specimen must be prepared and cured according to Vibratory Hammer Compaction
    Procedure as stated previously.
    ta
    qa
    4 The triaxial testing of the specimens must be planned to take place within 48 72 hours after
    completion of the curing procedure. This delay must be kept as constant as possible. The
    as

    following steps describe the procedure taken to assemble specimen in the simple triaxial cell
    and the cell in the loading frame:
    se

    (a) Place the specimens, casing with tube, top disk and base plate in a climate chamber
    and condition them overnight at 25C.
    er

    (b) Lightly grease the sides of the top disk and base plate to reduce friction as much as
    ov

    possible.
    (c) Place the specimen in the middle of the base plate.
    o

    (d) Carefully introduce the casing, comprising the tube, around the specimen. Take care
    it

    not to damage the edges of the specimen during this procedure.


    et

    (e) Clamp the casing in position on to the base plate using simple mechanical clamps on
    m

    the casing.
    (f) Put the top disk on top of the specimen.
    (g) Place the cell in the hydraulic loading frame; adjust actuator position until visual
    contact is made with the loading ram.
    (h) Connect the air supply to the cell; open the regulator and valve on the cell pressure
    port until the cell pressure is stable at the desired level.
    (i) Set monotonic test parameters on the MTS controller including displacement rate of
    strain (2.1%), full-scale for the loading (10.0V = 98.1 kN) and half-scale for the
    displacement (10.0V = 40mm), and run the test

    5 Monotonic Triaxial Test: Select four specimens of comparable density, moisture content and
    conditioned at 25C. Assemble the specimen in the triaxial cell according to 4 ensuring the
    tube is air tight.
    QCS 2014 Section 06: Roadworks Page 42
    Part 08: Recycled and Stabilised Road Materials

    (a) Operate the testing system in displacement control mode. Ensure that there is
    sufficient space between the actuator and the reaction frame to accommodate the
    triaxial cell. Place the triaxial cell in the hydraulic loading frame.
    (b) Adjust the actuator position until visual contact is made with the loading ram. Monitor
    the load cell reading to prevent loading of the specimen during this process. Connect
    the air supply to the cell pressure port. Open the valve on the cell pressure port and
    open the regulator until the cell pressure is stable at the desired level. The cell
    pressures for a series of monotonic tests are 0 kPa, 50kPa, 100 kPa and 200 kPa.
    (c) Test the first specimen without confinement pressure (0 kPa). Begin the test by
    compressing the specimen at a constant rate of displacement of 2.1%. Record the
    load versus displacement during the test with a minimum sampling rate of 10 Hz, as
    well as the cell pressure, temperature and specimen identifier.
    (d) Stop the test and the recording when the total displacement exceeds 18 mm (6%

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    strain) or when the specimen bulges excessively before the end displacement is

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    reached.

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    (e) Repeat this procedure for other three specimens until all specimens have been tested
    at the four levels of confinement pressures.

    6
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    Remove the specimens after completion of test after completion of a test. Hold the actuator
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    to its current position, close the valve on the cell pressure port and release the cell pressure
    by disconnecting the pressure supply tube to the cell (if possible speed up the pressure
    release by applying suction). Return the actuator to a position whereby the cell can easily be
    as

    removed from the loading frame. Remove the top disk. Clean the top disk and wipe off any
    grease. Unclamp the casing and lift the casing with tube from the cell base. Clean the tube
    se

    from possible remains of the deformed specimen (it is not necessary to remove the tube
    from the casing). Remove the tested specimen from the base plate. Place it in the plastic
    er

    bag and seal. Clean the base plate and wipe off any grease.
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    7 When all the specimens have been tested, remove the tested specimens one by one from
    the plastic bags. Break the tested specimens up and sample between 500 and 1000 gr. of
    o

    material from the middle of the specimen. Use this sample to determine the moisture content
    it

    of each specimen.
    et

    8 Calculations:
    m

    (a) Determine the applied failure load Pa,f for each specimen tested. The applied failure
    load is defined as the maximum applied load during the test. Calculate the applied
    failure stress a,f :

    a,f

    where: a,f = applied failure stress [kPa]


    Pa,f = applied failure load [N]
    2 2
    A = end area of a cylindrical specimen at beginning of [m ] or mm ??
    test
    QCS 2014 Section 06: Roadworks Page 43
    Part 08: Recycled and Stabilised Road Materials

    (b) Calculate the major principle stress at failure 1,f for each tested specimen:
    1,f = a,f + dw

    where: 1,f = major principle stress at failure [kPa]


    a,f = applied failure stress [kPa]
    dw = pressure resulting from dead weight of top disk and [kPa]
    loading ram
    (c) The relationship between 1,f and confinement stress (3)is determined by:
    1,f = A.3+B

    A
    where:

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    Values of A and B can be determined by performing a linear regression analysis on the

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    four combinations of 1,f and 3 per mix.
    (d) Values of [] and C [kPa] can be calculated as follows:

    where:

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    qa
    C
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    9 Report the following in the table format as illustrated in


    se

    10 Table 8. 8 Format Report for Simple Triaxial Test below:


    er

    (a) Specimen number or identifier;


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    (b) Confinement pressure (3);


    (c) Applied stress at failure (a,f);
    o

    (d) Major principal stress at failure (1,f);


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    et

    (e) Cohesion, C [kPa];


    Angle of internal friction, []; and
    m

    (f)
    2
    (g) Coefficient of variance, R

    11 Plot the Mohr Circles and the Mohr-Coulomb failure envelope as shown in Figure 7.4
    Example of Mohr Circle Plot, noting:
    (a) The centre of Mohr circle must be on the abscissa and is given by (1,f + 3)/2;
    (b) The radius of such circle is (1,f - 3)/2;
    (c) Angle of internal friction is the angle of the Mohr-Coulomb failure envelope (failure
    line);
    (d) The failure line intersects with ordinate at the cohesion value.
    QCS 2014 Section 06: Roadworks Page 44
    Part 08: Recycled and Stabilised Road Materials

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    Figure 7.4 Example of Mohr Circle Plot

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    Table 8. 8 Format Report for Simple Triaxial Test
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    Applied Principle
    Confining Internal
    Specimen Stress at stress at Correlation
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    Pressure, Cohesion Friction


    No. Failure Failure Coefficient
    3 Angle
    a,f 1,f
    er

    2
    [kPa] [kPa] [kPa] [kPa] [] [R ]
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    QCS 2014 Section 06: Roadworks Page 45
    Part 08: Recycled and Stabilised Road Materials

    8.7.15 Using Laboratory Test Results For Estimating Structural Layer Coefficients

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    Notes:
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    The minimum Retained Tensile Strength (%) requirement should be 75%.


    et

    The following minimum compaction requirements are recommended:


    m

    Material Type BSM3 BSM2 BSM1

    Percentage of Modified AASHTO


    > 97% > 100% > 102%
    compaction T180

    The material passing the 0.075mm sieve to be >2% for BSM-emulsion and >4% for
    BSM-foam.
    The maximum recommended addition of cement (active filler) is 1% by mass.
    Materials with a Plasticity Index > 10 to be pre-treated with hydrated lime to reduce
    the PI to <6.
    QCS 2014 Section 06: Roadworks Page 46
    Part 08: Recycled and Stabilised Road Materials

    8.7.16 Proforma Report Sheet For Its Testing


    The report sheet shown below may be used for all ITS tests, regardless of whether the tests
    were carried out for mix design purposes or for testing field samples.

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    QCS 2014 Section 06: Roadworks Page 47
    Part 08: Recycled and Stabilised Road Materials

    8.7.17 Laboratory Equipment Requirements

    1 Laboratory Equipment For Soils Testing

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    QCS 2014 Section 06: Roadworks Page 48
    Part 08: Recycled and Stabilised Road Materials

    2 Additional Laboratory Equipment for Cement or Lime Stabilisation

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    QCS 2014 Section 06: Roadworks Page 49
    Part 08: Recycled and Stabilised Road Materials

    3 Additional Laboratory Equipment for Bitumen Stabilisation

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    END OF PART
    QCS 2014 Section 06: Roadworks Page 1
    Part 09: Recycled Aggregate for Roadworks

    9 RECYCLED AGGREGATE FOR ROADWORKS ................................................................... 2


    9.1 GENERAL ---------------------------------------------------------------------------------------------- 2
    9.1.1 Scope 2
    9.1.2 References 2
    9.1.3 Definitions 3
    9.2 SOURCE ----------------------------------------------------------------------------------------------- 3
    9.3 APPLICATIONS -------------------------------------------------------------------------------------- 3
    9.4 RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS ------------ 4
    9.4.1 Requirements of Materials 4
    9.4.2 Compaction of Fill Material 5
    9.5 RECYCLED AGGREGATE FOR SUB-BASE MATERIAL ---------------------------------- 5

    .
    9.6 RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN

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    VILLAGE AREAS AND TEMPORARY ROADS ----------------------------------------------- 6

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    QCS 2014 Section 06: Roadworks Page 2
    Part 09: Recycled Aggregate for Roadworks

    9 RECYCLED AGGREGATE FOR ROADWORKS

    9.1 GENERAL

    9.1.1 Scope

    1 The conditions of this part cover the requirements of recycled aggregate obtained from
    demolition and excavation waste for use in roadworks.

    2 Related Parts are:


    Part 1, General
    Part 3, Earthworks
    Part 4, Unbound Pavement Materials

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    9.1.2 References

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    1 The following standards are referred to in this Part :
    ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of

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    Sodium Sulfate or Magnesium Sulfate
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    ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size
    Coarse Aggregate by Abrasion and Impact in the Los Angeles
    Machine
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    BS EN 933 Part 1 .......Determination of particle size distribution - Sieving method


    Aggregates
    se

    ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size


    Coarse Aggregate by Abrasion and Impact in the Los Angeles
    er

    Machine
    BS 1377 Part 4 ...........Methods of test for Compaction-related tests, California Bearing Ratio
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    (CBR) of Laboratory-Compacted Soils


    ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
    Aggregate
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    BS 1377 Part 3 ...........Standard Test Methods for Classification tests, Liquid Limit, Plastic
    Limit, and Plasticity Index of Soils
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    BS EN 933 Part 3. ......Methods of test for Determination of particle shape - Flakiness index
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    BS EN 933 Part 4. ......Methods of test for Determination of particle shape - Shape index
    BS EN 933 Part 5 .......Methods of test for Determination of percentage of crushed and
    broken surfaces in coarse aggregate particles.
    BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and
    electro-chemical tests
    BS EN 933-11:2009 ...Tests for geometrical properties of aggregates. Classification test for
    the constituents of coarse recycled aggregate
    BS EN 1097-2:2010...Tests for mechanical and physical properties of aggregates. Methods
    for the determination of resistance to fragmentation
    QS 29 / 2012 ..............The general Conditions For Recycled Aggregate Obtained From
    Building Demolition
    QCS 2014 Section 06: Roadworks Page 3
    Part 09: Recycled Aggregate for Roadworks

    9.1.3 Definitions

    1 Demolition Waste: Waste Material obtained from Excavated and/or demolished concrete
    structures.

    2 Concrete Demolition Waste : Waste Produced by demolition of concrete structures in


    general.

    3 Demolition Waste from Hard Concrete : Waste obtained from demolition of hard concrete
    members such as columns, foundations and other mass concrete blocks.

    4 Excavation Waste : Waste obtained from excavated materials.

    5 Mixed Demolition Waste : Waste material obtained from both excavated and demolished
    concrete structures.

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    6 Mixed Aggregate : Recycled fine and coarse Aggregate combined together.

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    7 Recycled Aggregate: a materials produced by the reprocessing of reclaimed construction
    and demolition waste. These include but are not limited to asphalt planings (i.e. the asphalt
    layers of roads removed during roadworks, also known as RAP Reclaimed Asphalt

    ta
    Pavement), fill, selected fill, granular subbase and rock from construction excavations.
    qa
    9.2 SOURCE

    1 The debris pieces of blocks collected from road demolitions in various places should be
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    stock piled at suitable location where different types of materials can be separated.
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    2 The clean, tough, hard, durable, free from organic material and uncoated particles containing
    no harmful materials in quantities sufficient to adversely affect construction works shall be
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    stock piled separately according to the required nominal sizes. The material free from pieces
    of steel, plastic and wood.
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    3 The sources of aggregate should be regularly and thoroughly investigated to ensure the
    quality of material is satisfactory. The aggregate shall be non-plastic and chemically stable.
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    9.3 APPLICATIONS
    et

    1 Carefully selected recycled aggregate can be used in many applications as shown below.
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    (a) For Non-structural Concrete (Grade SRC 20) for backing of kerbs, channels, edging
    and quadrant in road work.
    (b) For manufacture of Hollow & Solid Blocks and Paving blocks for pedestrians.
    (c) For Earth works related to roads.
    (d) For Aggregate of sub-base materials.
    (e) For Minor Roads of village areas and temporary roads.

    2 Recycled materials from construction or a construction process, or from existing pavement


    layers shall be separated according to type for processing. The separate processed
    materials shall be stored in stockpiles of no greater than 4000 tons and quarantined for
    testing and approval by the Engineer prior to use.
    QCS 2014 Section 06: Roadworks Page 4
    Part 09: Recycled Aggregate for Roadworks

    3 Samples shall be taken of the recycled aggregate constituents for classification by hand-
    sorting the coarse aggregate particles in accordance with BS EN 933-11. The test shall be
    carried out by a suitably trained laboratory technician who has demonstrated competence in
    classifying the constituent classes in accordance with the test method.

    4 Testing frequency shall be according to parts 3 and 4 of this section unless otherwise stated
    by the Engineer.

    5 Recycled aggregate shall be free from non-aggregate constituents such organics and shall
    have a minimum amount of deleterious material which may affect its reuse.

    6 The Percentage use of recycled aggregate shall not exceed the following:
    (a) A maximum of 50% of recycled fine, and/or coarse and/or mixed aggregates whether
    obtained from Concrete or mixed waste can be used for concrete works of less than
    20 MPa strength or any other construction works but not for asphalt layers.

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    (b) It is not allowed to use recycled Aggregate obtained from concrete or mixed demolition

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    wastes in asphalt mixes. Only Recycled Aggregate from excavated material can be

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    used in asphalt mixes.
    (c) A maximum of 100% of recycled aggregate obtained from excavated material can be
    used in any of the above mentioned construction works.
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    9.4 RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS

    9.4.1 Requirements of Materials


    as

    1 Recycled material shall be tested according to the relevant parts of BS 1377 and shall be
    se

    within the limits of following table:


    Table 9.5
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    Specifications of Recycled Aggregate for use in


    Earth Works Related to Roads
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    General Fill
    Selected Fill
    Requirement (Filling on low level
    o

    ( Sub-grade)
    areas)
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    Grading Standard Standard


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    Particle Size Less than 75mm Less than 75mm


    m

    Organic Material (%) 2 max 2 max


    Liquid Limit (%) 40 max 35max
    Plasticity Index (%) 11 max 10 max
    Material Passing 0.075 mm (%) 40 max 35 max
    Water Soluble Salts (%) 5 max 5 max
    Acid Soluble Salts (%) 10 max 10 max
    Soaked CBR Value - More than 15
    Swell (%) - 2 max
    Tree and Plant Stumps Free Free
    Perishable Materials Free Free
    Materials Subject to Spontaneous
    Free Free
    Combustion
    Material From Sabkha and Marshes Free Free
    QCS 2014 Section 06: Roadworks Page 5
    Part 09: Recycled Aggregate for Roadworks

    9.4.2 Compaction of Fill Material

    1 All Fill materials shall be placed in loose layers within the effective range of compaction of
    the approved plant. The maximum permissible loose layer thickness shall be limited to
    200mm.

    2 The fill material shall be watered and mixed as necessary to ensure that prior to compaction,
    the moisture content of the whole layer 3% of the optimum moisture content obtained at the
    laboratory compaction test (LCT). The compaction of layer shall continue until a density of at
    least 95% of the maximum dry density of LCT.

    3 No layer shall be covered by the next layer until it has been tested, inspected and approved
    by the Engineer.

    9.5 RECYCLED AGGREGATE FOR SUB-BASE MATERIAL

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    1 The following table illustrates the material requirements for unbound materials for roadworks.

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    Table 9.6
    Requirements of Recycled Aggregate for Roadworks Unbound Layers

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    Raw Materials Production
    Requirement Aggregate
    Fine Aggregate Coarse Aggregate
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    Sub-Base
    Grading Standard Standard Class C
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    Particle Size Less than 4.75mm More than 4.75mm


    er

    OR Less Than 4.0mm More than 4.0mm


    Organic Material (%) 0.5 max Free Free
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    Liquid Limit (%) material


    -
    passing 0.425 or 0.500mm 25 max 25 max
    Plasticity Index (%)material
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    -
    passing 0.425 or 0.500mm 6 max 6 max
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    MaterialPassing0.075mm (%) - - -
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    Water Soluble Chlorides (%) - 1.0 max 1.0 max


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    Acid Soluble Chlorides (%) - 2.0 max 2.0 max


    Water Soluble Sulphates (%) - 1.5 max 1.5 max
    Acid Soluble Sulphates SO 3(%) - 3.0 max 3.0 max
    Soaked CBR Value - - 80 min
    Swell (%) - - 1.0 max
    Tree and Plant Stumps - Free Free
    Perishable Marshes - Free Free
    Materials subject to
    - Free Free
    Spontaneous combustion
    Material from Sabkha and
    - Free Free
    Marshes
    Clay Balls Free Free Free
    Ratio of Passing 0.075mm &
    66 - -
    0.425mm (%)
    Flakiness Index (%) - 35 max 35 max
    QCS 2014 Section 06: Roadworks Page 6
    Part 09: Recycled Aggregate for Roadworks

    Raw Materials Production


    Requirement Aggregate
    Fine Aggregate Coarse Aggregate
    Sub-Base

    Elongation Index (%) - 40 max 40 max


    Los Angeles Abrasion (%) - 40 max 40 max
    Soundness - magnesium
    - 20 max 20 max
    sulphates, 5 cycles (%)
    Sand Equivalent Value - - 25 min

    2 Mix Designs
    (a) The recycled aggregate shall be used in aggregate sub-base and base courses. The

    .
    fine and course aggregate shall be combined proportionately in order to achieve the

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    following class of grading:

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    Table 9.7
    Gradation of Recycled Aggregate for use in Subbase Layers

    ta
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    Percentage Passing
    BS EN Sieve (mm) ASTM Sieve (mm) (by Weight)

    Class C
    as

    63.0 63.0 -
    se

    - 50.0 -
    40.0 37.5 -
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    - 25.0 100
    20.0 19 90-100
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    10.0 9.5 50-85


    4.0 4.75 35-65
    2.0 2.36 25-50
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    0.500 0.425 15-30


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    0.063 0.075 5-15


    et

    3 Screening and Mixing


    m

    (a) Screening is required for recycled materials used in the road base and sub base to
    ensure that the designated gradation is attained.
    (b) Central Mixing plant is required for the mixing of materials.

    9.6 RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN


    VILLAGE AREAS AND TEMPORARY ROADS

    1 Recycled Aggregate for use in Asphalt layers of temporary and minor roads in village areas
    shall be reclaimed from excavated natural soil which is mechanically and chemically stable
    and of specifications in the following table:
    QCS 2014 Section 06: Roadworks Page 7
    Part 09: Recycled Aggregate for Roadworks

    Table 9.9
    Specification of Recycled Aggregate for use in
    Asphalt Layers for Village and Temporary Roads
    Recycled Aggregate
    Requirement
    Fine Aggregate Coarse Aggregate
    Grading Standard Standard
    Particle Size Less than 2.36 mm More than 2.36mm
    Organic Material - including wood and materials
    0.5 max 0.5 max
    prone to disintegration (%)
    Water Absorption Saturated surface dry (%) 2.0 max
    Liquid Limit - -
    Plasticity Index (%) 4 max -
    MaterialPassing0.075mm (%) - -

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    Acid Soluble Chlorides (%) 2.0 max 2.0 max

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    Acid Soluble Sulphates SO 3 (%) 3.0 max 3.0 max

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    Materials subject to Spontaneous combustion - Free
    Materials from Sabkha and Marshes - Free
    Clay Balls
    Flakiness Index (%) ta Free
    -
    Free
    35 max
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    Elongation Index (%) - 40 max
    Los Angeles Abrasion (%) - 40 max
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    Crushing Value (%) 25 max


    Soundness - magnesium sulphates, 5 cycles (%) 18 max
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    Sand Equivalent Value 30 min -


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    2 The different sizes of material shall be separated by screening and re-combined together to
    produce the all-in Recycled crushed aggregate, which shall achieve the following grading
    ov

    limits :
    Table17.8
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    Gradation of Recycled Crushed Aggregate for use in


    it

    Asphalt Layers for Village and Temporary Roads


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    BS EN Sieve (mm) BS Sieve (mm) Percentage Passing (by weight)


    m

    63.0 50.0 100


    40.0 37.5 95-100
    20.0 19.0 60-80
    10.0 9.5 40-60
    4.0 4.75 25-40
    2.0 2.36 15-30
    0.500 0.600 8-22
    0.063 0.075 5-12

    3 Recycled aggregate for use in Asphalt layers of minor roads in village areas and temporary
    roads shall be nonplastic.

    4 The material shall wet during transporting and spreading in order to avoid segregation.

    END OF PART
    QCS 2014 Section 07: Green Constructions Page 1
    Part 01: Introduction

    1 INTRODUCTION ..................................................................................................... 2
    1.1 GREEN CONSTRUCTION ...................................................................................... 2
    1.1.1 Green Construction and Sustainability 2
    1.1.2 Reference 2
    1.1.3 Green Construction Regulations and Environmental Assessment Tools 2
    1.1.4 Green Building Definition 2

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 01: Introduction

    1 INTRODUCTION

    1.1 GREEN CONSTRUCTION

    1.1.1 Green Construction and Sustainability

    1 Buildings, infrastructure and the environment are inextricably linked. Energy, water, materials
    and land are all consumed in the construction and operation of buildings and infrastructure.
    These built structures in turn become part of living environment, affecting living conditions,
    social well-being and health. It is important to explore environmentally and economically
    sound design and development techniques in order to design buildings and infrastructure that
    are sustainable, healthy and affordable, and encourage innovation in buildings and
    infrastructure systems and designs.

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    2 The concept of sustainability in building and construction has evolved over many years. The

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    initial concept was on how to deal with the issue of limited resources, especially energy, and

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    on how to reduce impacts on the natural environment. Emphasis was placed on technical
    issues such as materials, building components, construction technologies and energy related
    design concepts. Recently non-technical issues become appreciated such as economic,

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    social sustainability and cultural heritage aspects of the built environment. Also, there are
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    greater attention to create more green buildings by upgrading the existing buildings through
    the application of new developments or the invention and use of innovative technologies for
    energy and material savings.
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    1.1.2 Reference
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    1 The following documents are referred to in this section:


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    Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for
    ov

    Research and Development, Qatar, formerly known as (QSAS) (Note: QCS reference shall
    be limited only to this particular version of GSAS and non-other)
    o

    1.1.3 Green Construction Regulations and Environmental Assessment Tools


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    et

    1 Many countries have developed their own standards for green building or energy efficiency
    m

    for buildings and Building Environmental Assessment tools. Now there are many of building
    rating systems tools and guidelines in the world currently in use. A new sustainability
    assessment system known as GSAS (GLOBAL Sustainability Assessment System) is
    referred to herein in this document.

    1.1.4 Green Building Definition

    1 Green building is the process through which buildings are designed, constructed and
    operated to reduce natural resources consumption, eliminate environmental degradation and
    enhance social and economic aspects of humans.

    END OF PART
    QCS 2014 Section 07: Green Constructions Page 1
    Part 02: QCS Green Building

    2 QCS GREEN BUILDING ......................................................................................... 2


    2.1 SCOPE .................................................................................................................... 2
    2.1.1 General 2
    2.1.2 References 2
    2.2 QCS GREEN BUILDING REQUIREMENTS ............................................................ 3
    2.2.1 Types of Buildings 3
    2.2.2 QCS Green Building Categories & Criteria 3
    2.2.3 Submittal Requirements 5

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 02: QCS Green Building

    2 QCS GREEN BUILDING

    2.1 SCOPE

    2.1.1 General

    1 This section specifies minimum environmental performance requirements that apply to the
    design, construction and operations of new buildings.

    2 The minimum environmental performance requirements apply to 8 building typologies only


    (Section 2.2.1) and have been specified for eleven environmental performance criteria (Table
    1).

    3 The environmental performance criteria apply to all new buildings for those building

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    typologies specified and shall apply to:

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    (a) Buildings under design but not yet constructed (i.e. pre-construction);
    (b) Buildings under construction; and
    (c) Buildings constructed prior to hand over.
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    4 For buildings under construction or constructed and not handed over, the minimum
    environmental performance requirements shall apply as far as is reasonably possible without
    the need to undertake a major re-design and retrofit. Where building owners, designers or
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    contractors, etc. judge that any re-design or retrofit to meet the environmental performance
    requirements specified herein is not reasonable, the relevant Qatari authorities / government
    se

    agencies reserve the right to ask for a justification to explain such a decision.
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    5 The Engineer shall specify the applicable Green Building Assessment System for the QCSs
    Building typologies and to assess compliance with QCSs Green Building Requirements.
    ov

    6 The minimum environmental performance requirements specified herein have been derived
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    from the Global Sustainability Assessment System (GSAS) v2.1-2013.


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    7 The Engineer shall ensure compliance with QCSs minimum sustainable building
    et

    requirements or higher specified by the relevant authorities or the Engineer.


    m

    8 QCS 2014 encourage the use of any environmental or sustainability performance criteria in
    addition to those environmental performance criteria specified to help design, construct and
    operate better buildings.

    2.1.2 References

    1 The following documents are referred to in this section:

    Global Sustainability Assessment System (GSAS) v2.1-2013, Gulf Organisation for Research
    and Development, Qatar
    QCS 2014 Section 07: Green Constructions Page 3
    Part 02: QCS Green Building

    2.2 QCS GREEN BUILDING REQUIREMENTS

    1 The values listed herein for the Commercial, Health Centres, Education, Mosques, and Light
    Industries Schemes and Typologies shall be considered as the minimum requirements for
    the applicable criteria (Table 3).

    2.2.1 Types of Buildings

    1 COMMERCIAL: Types include Spaces that Serves various functions such as offices,
    2
    conference rooms, foyers, retail spaces, and ancillary areas, with built up area of 10000 m
    or more.

    2 GOVERNMENTAL BUILDINGS: Types include Capitol, Diplomatic Buildings, Statehouses,


    Courthouses, Municipalities, Post offices, etc.

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    3 PUBLIC BUIDLINGS: Types include:

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    rw
    (a) RAIL BUILDINGS: Types include spaces that serve various functions of a railway
    station such as but not necessarily limited to platform/concourse, offices, station
    control room, ticketing, retail, food/beverage areas, and ancillary areas.
    (b) ta
    SPORTS: Facilities include indoor or outdoor competition areas, fitness suites, locker
    qa
    facilities, retail spaces, offices, restaurants, and common areas
    (c) EDUCATION BUILDINGS: Types include educational facilities for students in
    th
    as

    kindergarten through 12 grade as well as college and university facilities. This


    includes classrooms, libraries, auditoriums, cafeterias, kitchens, offices, and other
    se

    spaces that are part of academic buildings.


    (d) MOSQUES AND OTHER RELIGIOUS BUILDINGS: Types include the building
    er

    containing the congregational worship areas.


    ov

    (e) HOSPITALS AND HEALTH CENTERS BUILDINGS: Types include specialist


    hospitals, general hospitals, out-patient hospitals, and primary care health centres.
    o

    4 LIGHT INDUSTRIES BUILDINGS: Types include both operational and office areas as well as
    it

    the general building as a whole.


    et

    2.2.2 QCS Green Building Categories & Criteria


    m

    1 The minimum QCSs requirements unless other values specified by the relevant authorities.
    Table 1: Green Building Categories & Criteria

    QCS Category Criteria Minimum Requirements * Building Typologies

    Commercial, Governmental
    Energy Demand
    Education, Mosques &
    Performance
    ENERGY EPC 1.0 other religious buildings,
    Energy Delivery Light Industry, Health
    Performance Centres, Railways, Sports

    WPC 1.0
    Commercial,
    Governmental, Education,
    WATER Water Consumption Mosques, Light Industries,
    Health Centres,
    Railways, Sports
    QCS 2014 Section 07: Green Constructions Page 4
    Part 02: QCS Green Building

    QCS Category Criteria Minimum Requirements * Building Typologies

    Commercial, Light Industry,


    PMV 2.0
    Governmental
    80 ADPI Education, Mosques
    Comply with ASHRAE
    Health Centres
    Standards
    Thermal Comfort Comply with ASHRAE
    Railways
    Standards
    PMV 2.0 office spaces
    worst case heat load 1.6 Sports
    Exposed Spectator Seating

    Commercial,
    Natural Ventilation Can be
    Governmental, Education,
    Utilized(x)
    Mosques,
    0 < X ) month of the year(

    .
    Light Industry

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    INDOOR

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    ENVIRONMENT Comply with ASHRAE
    Natural Ventilation Health Centres
    Standard

    rw
    Natural Ventilation Can be
    Utilized(x) Sports
    0 < X (month of the year)

    Standard ta
    Comply with ASHRAE
    Railways (above ground)
    qa
    no existence of equipment Commercial, Education,
    with efficiency less than Mosques,
    Mechanical Ventilation
    specified in ASHRAE 90.1- Light Industry
    2010 Health Centres, Railways
    as

    Commercial, Governmental
    Education,
    se

    Mosques,
    Low-Emitting Materials VOC_emi_total 100%
    Light Industry
    Health Centres, Sports,
    er

    Railways
    Commercial, Governmental
    ov

    % of Construction Expenditure Education,


    Support of National Benefiting National Economy Mosques,
    (GCC) Economy (x) Light Industry
    o

    CULTURAL & 20 X Health Centres, Railways,


    ECONOMIC Sports
    it

    VALUE Commercial, Governmental


    et

    Education,
    Cultural Identity & To be defined & assessed by
    Mosques,
    m

    Heritage Certification Authority


    Light Industry
    Health Centres, Railways
    Commercial, Governmental
    Education,
    MANAGEMENT Recycling Management Plan Mosques,
    Recycling Management
    & OPERATION demonstrates Compliance Light Industry
    Health Centres, Sports,
    Railways
    Commercial, Governmental
    Education,
    Performance Indicator (X) Mosques,
    MATERIALS Regional Materials
    X < 30 Light Industry
    Health Centres, Railways,
    Sports
    QCS 2014 Section 07: Green Constructions Page 5
    Part 02: QCS Green Building

    2.2.3 Submittal Requirements

    1 Building owners, designers or contractors, etc. shall provide the relevant authorities with a
    report that shows how the minimum environmental requirements have been met. The report
    shall include:

    (a) All raw data used to performance calculations;


    (b) All calculations used to derive results against the environmental criteria specified (and /
    or copies of relevant GSAS calculator tools where appropriate);
    (c) All specifications where relevant of construction materials, equipment, fixtures and
    fittings, etc;
    (d) Details of suppliers / service providers with evidence that purchases have been made
    or services commissioned, etc.

    .
    (e) All other information necessary to demonstrate how the environmental performance

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    requirements have been met.

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    END OF PART
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    QCS 2014 Section 07: Green Constructions Page 1
    Part 03: Energy

    3 ENERGY [E] ............................................................................................................ 2


    3.1.1 Scope 2
    3.1.2 Reference 2
    3.1.3 Abbreviations 2
    3.2.1 Scope 3
    3.2.2 Description 3
    3.2.3 Measurement Principle 4
    3.2.4 Measurement ( EPCnd) 4
    3.2.5 Score ( EPCnd) 4
    3.3.1 Scope 4
    3.3.2 Description 5
    3.3.3 Measurement Principle 5
    3.3.4 Measurement (EPCdel) 5

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    3.3.5 Score (EPCdel) 6

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 03: Energy

    3 ENERGY [E]

    3.1 GENERAL

    3.1.1 Scope

    1 The Energy category consists of factors associated with energy demand of buildings, the
    efficiency of energy delivery, and the use of fossil energy sources that result in harmful
    emissions and pollution.

    (a) Impacts: Negative impacts resulting from energy use and unsustainable practices
    include:
    (i) Climate Change

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    (ii) Fossil Fuel Depletion

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    (iii) Air Pollution

    rw
    (iv) Human Comfort & Health
    (b) Mitigate Impact: Factors that could mitigate environmental impacts due to energy use
    include:
    ta
    qa
    (i) Designing the building to lower its energy demand
    (ii) Selecting efficient building systems
    as

    (iii) Lowering the demand on non-renewable sources of energy thereby reducing


    harmful emissions and depletion of fossil fuels
    se

    (iv) Minimizing the amount of harmful substances produced by the energy delivery
    er

    systems and the energy supply network


    ov

    (c) Energy is sub-categorised as follows:


    (i) Energy Demand Performance
    o

    (ii) Energy Delivery Performance


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    et

    3.1.2 Reference
    m

    1 The following documents are referred to in this section:

    Global Sustainability Assessment System (GSAS) V2.1 2013, Gulf Organization for
    Research and Development , Qatar (Note: QCS reference shall be limited only to this
    particular version of GSAS and non-other).

    3.1.3 Abbreviations

    1 The following abbreviations are defined for use in this section.


    EPC Energy Performance Coefficient
    EPCnd Energy Demand Performance
    EPCdel Energy Delivery Performancet
    EPCp Primary Energy Performance
    fop Operation factor for a particular Building category
    QCS 2014 Section 07: Green Constructions Page 3
    Part 03: Energy

    Edelivery The delivered energy is defined as the supplied energy To the


    technical building systems through the system boundary, to satisfy
    2
    the uses of the building in KWh/m /yr.
    Eref_del The reference value used in the GSAS scoring method for the
    2
    Delivered energy for the building type in KWh/m /yr.
    EP
    2
    The total primary energy consumed for the building in KWh/m /yr.
    Eref_p the reference value used in the GSASscoring method for primary
    2
    Energy for the building type in KWh/m /yr.
    CO2
    2
    The emitted mass of CO2 in g/m /yr. calculated from the net
    delivered Energy and emission coefficient. The emission
    coefficient includes the CO2 emissions associated with the primary
    energy consumed for the building.
    CO2ref the reference value used in the GSASscoring method for CO2
    emissions for the building type in g/m2/yr.

    .
    Qdesign
    2
    the building thermal energy demand in kwh/m /yr. which takes into

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    account the energy losses (transmission and ventilation), heat
    gains (solar, internal and system heat losses), and the dynamic

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    parameter (loss utilization factor).
    Qref_nd the reference value used in the GSAS Scoring method for energy

    NOX,SOX ta 2
    demand for the building type in kwh/m /yr.
    2
    The emitted masses of NOX & SOX in gm./m /yr. calculated from
    qa
    the net delivered energy and emission coefficients.
    NOXref,SOXref the reference values used in the GSAS scoring method for NOX &
    as

    2
    SOX emissions for the building type in gm./m /yr.

    3.2 ENERGY [E.1] ENERGY DEMAND PERFORMANCE


    se

    3.2.1 Scope
    er

    1 The energy demand performance shall be measured for the following categories of
    ov

    buildings:
    o

    Table 1: Building Typologies


    it

    Commercial
    et

    Governmental
    m

    Education
    Mosques & other religious buildings
    Light Industry
    Health Centres
    Railways Buildings
    Sports

    3.2.2 Description

    1 Establish energy demand performance levels for the building in order to reduce
    environmental and economic impacts associated with excessive energy use.
    QCS 2014 Section 07: Green Constructions Page 4
    Part 03: Energy

    3.2.3 Measurement Principle

    1 The Engineer shall Calculate Building performance in relation to the baseline as specified
    below. All calculations will adhere to the GSAS Energy Application document.

    3.2.4 Measurement ( EPCnd)

    1 The Engineer shall calculate the EPCnd value based on building data and cooling energy
    needs of the project as per the energy performance standard calculation tool (EPSCT).

    2 Calculated EPCnd = Qdesign / Qref_nd The Qdesign is calculated according to the GSAS Energy
    Application document.

    3 Commercial & Governmental (with baseline reference) Qref_nd = 125 [kWh/m/yr].

    l .
    4 Education: With Baseline reference Qref_nd = 122* fop.education [kWh/m/yr]. where fop.education is

    .l.
    the operation factor for education typologies. The Qdesign and fop,school are calculated according

    rw
    to the GSAS Energy Application document.

    5 Mosques & other religious buildings: With Baseline reference Qref_nd = 170 [kWh/m/yr] . The

    ta
    Qdesign is calculated according to the GSAS Energy Application document.
    qa
    6 Health Centers: The Qref_nd are area weighted average calculated according to the reference
    guidelines document.
    as

    7 Railways: The Qref_nd are area weighted average calculated according to the refference
    guidelines document.
    se

    8 Sports : the Engineer shall determine energy demand performance in two steps. Step 1, the
    er

    project will use the Energy Performance Calculator to determine the Energy demand (Q nd.fc,I)
    ov

    for each functional component (FC) of the project. Step 2, the project will enter the Qnd,fc,I for
    each FC in the composition sheet in the energy calculator to determine the aggregated
    criterion score for the entire sports facility.
    it o

    9 Light Industry : With Baseline reference Qref_nd = 475 [kWh/m/yr.]


    et

    3.2.5 Score ( EPCnd)


    m

    1 The Recommended minimum requirement * value for EPCnd shall be as per table 2:
    Note : (*) minimum QCSs requirements unless other values specified by the relevant
    authority
    Table 2: EPCnd Values

    EPCnd Value 0.8 < EPCnd 1.0

    3.3 ENERGY [E.2]: ENERGY DELIVERY PERFORMANCE

    3.3.1 Scope

    1 The energy delivery performance shall be measured for the following categories of buildings:
    QCS 2014 Section 07: Green Constructions Page 5
    Part 03: Energy

    Table 3: Building Typologies


    Commercial
    Governmental

    Education
    Mosques & other religious buildings
    Light Industry
    Health Centres
    Railways Buildings
    Sports

    l .
    3.3.2 Description

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    1 The Engineer shall establish delivered energy performance levels of the project in order to
    reduce environmental and economic impacts associated with excessive energy use.

    3.3.3 Measurement Principle


    ta
    qa
    1 The Engineer shall calculate the building performance in relation to the baseline as specified
    below. All calculations will adhere to the GSAS Energy Application document.
    as

    3.3.4 Measurement (EPCdel)


    se

    1 The Engineer shall complete the Energy Performance Standard Calculation Tool (EPSCT) to
    determine the EPCdel value based on building data, HVAC specifications, lighting system,
    er

    and DHW system and energy generation.


    ov

    2 Calculated EPCdel =Edel / Eref_del the Edel is calculated according to the GSAS Energy
    Application document.
    it o

    3 Commercial & Governmental : with Baseline reference Eref_del = 89 [kWh/m/yr].


    et

    4 Education With Baseline reference Eref_del = 88* fop_education [kWh/m/yr]. where fop_education is the
    m

    operation factor forEducation Typologies. The Edelivery and fop,education are calculated according
    to the GSAS Energy Application document.

    5 Mosques & other religious buildings: With Baseline reference Eref_del = 82 [kWh/m/yr]. The
    Edelivery is calculated according to the GSAS Energy Application document.

    6 Light Industry: With Baseline reference Eref_del = 165 [kWh/m/yr].

    7 Sports Facilities: The Engineer shall determine energy delivery performance in two steps.
    Step 1, the Engineer shall use the Energy performance calculator to determine the delivered
    energy (Edel,fc,i) for each functional component (FC) of the project. Step 2, the Engineer shall
    enter the Edel,fc,I for each FC in the energy score calculator to determine the aggregated
    criterion score for the entire sports facility.
    QCS 2014 Section 07: Green Constructions Page 6
    Part 03: Energy

    3.3.5 Score (EPCdel)

    1 The Recommended minimum requirments* EPCdel value shall be categorised as per table
    4.
    Note : (*) minimum QCSs requirements unless other values specified by the relevant
    authority

    Table 4: EPCdel minimum required value

    EPCdel Value 0.8 < EPCdel 1.0

    END OF PART

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    QCS 2014 Section 07: Green Constructions Page 1
    Part 04: Water

    4 WATER [W] .............................................................................................................................. 2


    4.1.1 SCOPE 2
    4.1.2 REFERENCE 2
    4.2.1 SCOPE 2
    4.2.2 DESCRIPTION 3
    4.2.3 MEASUREMENT PRINCIPLE 3
    4.2.4 MEASUREMENT (WPC) 3
    *
    4.2.5 SCORE 4
    6 RAILWAY TEMINALS 5

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 04: Water

    4 WATER [W]

    4.1 GENERAL

    4.1.1 Scope

    1 The Water category consists of factors associated with water consumption and its
    associated burden on municipal supply and treatment systems.
    (a) Impacts: Environmental impacts resulting from water consumption and unsustainable
    practices include:
    (i) Water depletion

    (b) Mitigate Impact: Factors that could mitigate environmental impact and lower demand
    on water include:

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    (i) Specifying efficient plumbing fixtures

    rw
    (ii) Creating a system for the collection and storage of rainwater

    (iii) On-site treatment of water for later reuse

    (iv) ta
    Designing a landscaping plan that minimizes the need for irrigation.
    qa
    The recommended criteria is Water Performance Coefficient (WPC) [W.1]
    as

    4.1.2 Reference
    se

    1 The following documents are referred to in this section:


    Global Sustainability Assessment System (GSAS) - V2.1 2013, Gulf Organization for
    er

    Research and Development, Qatar (Note: QCS reference shall be limited only to this
    ov

    particular version of GSAS and non-other).

    4.2 WATER CONSUMPTION [W]


    it o

    4.2.1 Scope
    et
    m

    1 The Water consumption will be measured for the following categories of buildings listed in
    table 1:
    Table 1: Building Typologies
    Commercial
    Governmental
    Education
    Mosques & other religious buildings
    Light Industry
    Health Centres
    Railways Buildings
    Sports
    QCS 2014 Section 07: Green Constructions Page 3
    Part 04: Water

    4.2.2 Description

    1 Minimize water consumption in order to reduce the burden on municipal supply and
    treatment systems.

    4.2.3 Measurement Principle

    1 The Engineer shall demonstrate conservation in the use of water in relation to the baseline
    and targets outlined in the Water Consumption Calculator.

    4.2.4 Measurement (WPC)

    1 The Engineer shall determine cumulative water consumption [Water Performance Coefficient
    (WPC)] using the Water Consumption Calculator. Cumulative water consumption is

    .
    determined by several input parameters including:

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    (a) The project site area and the number of full time staff, students, or residents and

    rw
    visitors occupying the building
    (b) Specifications for plumbing fixtures
    (c) Landscaping and irrigation plan
    ta
    qa
    (d) Rain and storm water collection and reuse plan
    (e) Grey and black water treatment and reuse plan
    as

    2 Based on input parameters provided by the project, the application conducts multiple
    calculations to determine the buildings estimated water consumption. Three estimated
    se

    calculation values, Water Consumption for occupants (WCcal_occupant), Water Consumption for
    irrigation (WCcal_irrigation), Water Supply from reuse strategies (WScal_reuse) are computed by
    er

    the calculator. The annual net water demand is calculated by subtracting water supply
    ov

    (WScal_reuse) from the summation of water consumptions (WCcal_occupant + WCcal_irrigation). Then,


    the net water demand is compared against the summation of the two reference water
    consumption values (WCref_occupant + WCref_irrigation) to generate the Water Performance
    o

    Coefficient (WPC).
    it
    et
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    3 For each building type, the equations to calculate reference values apply to all buildings
    regardless of operating duration, occupancy density and site area. A different reference
    value will be calculated for project buildings with varying site and operational characteristics,
    and the resulting WPC will therefore be applicable across the entire spectrum of each
    building type.
    (a) The Referenced Water Consumption for Occupants is:
    WCref_occupant = A x Operating Hours x Occupants
    Where:
    Operating Hours = 8 (hours per day) x 20 (days per month) x 12 (months per year)
    QCS 2014 Section 07: Green Constructions Page 4
    Part 04: Water

    Occupants = The total number of full time employees per day + the total number of
    visitors per day
    (b) The Referenced Water Consumption for irrigation is:
    2
    WCref.,irrigation = B x 365 (days per year) x 24 (hours per day) x Site Area (m )
    Reference values A and B can be found for the different typologies in the following table:

    Table 2: Reference values A and B


    A B
    Commercial &
    0.006519 0.000034
    Governmental
    Education 0.008423 0.000001
    Mosques & other
    0.003888 0.000002

    .
    religious buildings

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    Light Industry 0.005355 0.000004

    rw
    Sports N/A N/A

    These typologies have multiple occupant reference values which are listed in further detail
    in the following sections.
    ta
    qa
    4 Education
    (a) Additional input parameters required:
    as

    (b) Number of staff and students occupying the building


    se

    5 Mosques:
    er

    Additional input parameters required:


    ov

    * Number of worshippers visiting the mosque, both on a daily basis and during times of
    full occupancy.
    o

    (a) The Referenced Water Consumption for Occupants is:


    it

    WCref_occupant = A No. Operating Hours_d No.Occupants_d) + (No. Operating


    et

    Hours_f x No. Occupants_f)


    m

    Notes:
    (i) Where No.Occupants_d is the number of daily worshippers, No.Occupants_f
    is the number of occupants during full occupancy.
    (ii) No.Operating Hours_d are normalized as 6 (hours per day) x 30 (days per
    month) x 12 (months per year)
    (iii) No.Operating Hours_f are normalized as 2 (hours per day) x 30 (days of
    Ramadan) + 52 (Friday prayers per year)

    6 Light Industry
    Additional input parameters required:
    Number of full time employees and visitors occupying the building
    *
    4.2.5 Score
    The minimum Requirement values by QCS for Water Performance Coefficient shall be:
    QCS 2014 Section 07: Green Constructions Page 5
    Part 04: Water

    Note : (*) minimum QCSs requirements unless other values specified by the relevant
    authority

    1 COMMERCIAL & GOVERNMENTAL


    Table 3: minimum score for commercial Typology

    WPC(X) Value 0.87 < X 1.0

    2 EDUCATION
    Table 4: minimum score for Education Typology

    WPC(X) 0.85 < X 1.0

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    3 MOSQUES

    rw
    Table 5: minimum score for Mosques Typology

    WPC(X) 0.89 < X 1.0


    ta
    qa
    4 LIGHT INDUSTRIES
    Table 6: minimum score for Light Industry Typology
    as

    WPC(X) 0.84 < X 1.0


    se

    5 HEALTH CENTRES
    er

    Table 7: minimum score for Health Centres Typology


    ov

    WPC(X) 0.84 < X 1.0


    o

    6 RAILWAY TEMINALS
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    et

    Table 8: minimum score for Railways Typology


    m

    WPC(X) 0.84 < X 1.0


    7 SPORTS FACILITIES

    Table 9: minimum score for Sports Typology

    WPC(X) 0.0 X < 0.5

    END OF PART
    QCS 2014 Section 07 : Green Constructions Page 1
    Part 05 : Indoor Environment

    5 INDOOR ENVIRONMENT [IE] ................................................................................................. 2

    5.1 GENERAL ................................................................................................................................ 2


    5.1.1 SCOPE 2
    5.1.2 REFERENCE 2

    5.2 INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT ........................................................ 3


    5.2.1 SCOPE 3
    5.2.2 DESCRIPTION 3
    5.2.3 MEASUREMENT PRINCIPLE 3
    5.2.4 MEASUREMENT (THERMAL COMFORT) 3
    *
    5.2.5 SCORE 4

    5.3 INDOOR ENVIRONMENT [IE.2] Natural Ventilation ............................................................... 5


    5.3.1 SCOPE 5

    .
    5.3.2 DESCRIPTION 5

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    5.3.3 MEASUREMENT PRINCIPLE 5
    5.3.4 MEASUREMENT (NATURAL VENTILATION) 6

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    5.3.5 SCORE* 6

    5.4 INDOOR ENVIRONMENT [IE.3] : Mechanical Ventilation ...................................................... 7


    5.4.1
    5.4.2
    SCOPE
    DESCRIPTION ta 7
    7
    qa
    5.4.3 MEASUREMENT PRINCIPLE 7
    5.4.4 MEASUREMENT (MECHANICAL VENTILATION) 7
    *
    5.4.5 SCORE (MECHANICAL VENTILATION) 8
    as

    5.5 INDOOR ENVIRONMENT [IE.4] Low-Emitting Materials ........................................................ 8


    se

    5.5.1 SCOPE 8
    5.5.2 DESCRIPTION 8
    er

    5.5.3 MEASUREMENT PRINCIPLE 8


    5.5.4 MEASUREMENT (VOC) 8
    ov

    5.5.5 SCORE (VOC) 9


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    QCS 2014 Section 07 : Green Constructions Page 2
    Part 05 : Indoor Environment

    5 INDOOR ENVIRONMENT [IE]

    5.1 GENERAL

    5.1.1 Scope

    1 The Indoor Environment category consists of factors associated with indoor environmental
    quality such as thermal comfort, air quality, acoustic quality, and light quality..
    (a) Impacts: Impacts resulting from ineffective control and design of the indoor
    environment include:
    (i) Climate Change
    (ii) Fossil Fuel Depletion

    .
    (iii) Air Pollution

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    (iv) Human Comfort & Health

    rw
    (b) Mitigate Impact: Factors that could improve indoor environmental quality include:
    (i) Monitoring air temperature and quality and adjusting or calibrating as
    appropriate
    ta
    qa
    (ii) Maximizing the time period that the building can utilize natural ventilation
    (iii) Designing an adequate mechanical ventilation system
    as

    (iv) Ensuring adequate illuminance levels for visiual performance and comfort
    se

    (v) Maximizing the use of natural lighting in interior spaces


    (vi) Providing for occupant comfort by minimizing glare
    er

    (vii) Maximizing views to the exterior for all occupants


    ov

    (viii) Controlling the amount of noise produced by or transferred from the building
    interior and exterior
    o

    (ix) Specifying materials with low VOC levels


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    et

    (x) Controlling indoor pollutants and sources of airborne contamination


    (c) The QCSs requirements for Sub-Indoor Environment criteria Includes:
    m

    (i) Thermal Comfort


    (ii) Natural Ventilation
    (iii) Mechanical Ventilation
    (iv) Low-Emitting Materials

    2 The Public and Government Buildings are to be considered as commercial for the purpose of
    Indoor Environment calculation as applicable.

    5.1.2 Reference

    1 The following documents are referred to in this section:


    QCS 2014 Section 07 : Green Constructions Page 3
    Part 05 : Indoor Environment

    Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for
    Research and Development (GORD), Qatar (Note: QCS reference shall be limited only to
    this particular version of GSAS and non-other), And American Society of Heating,
    Refrigerating and Air-Conditioning Engineers (ASHRAE)

    5.2 INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT

    5.2.1 Scope

    1 The Indoor Environment for Thermal Comfort shall be measured for the following categories
    of the buildings:

    Table 1: Building Typology

    Commercial

    l .
    .l.
    Governmental

    rw
    Education
    Mosques & other religious buildings
    Light Industry
    Health Centres ta
    qa
    Railways Terminals
    as

    Sports Facilities
    se

    5.2.2 Description

    1 The Project shall provide a thermaly comfortable environment to ensure the comfort and
    er

    health of building occupants.


    ov

    5.2.3 Measurement Principle


    o

    1 The Engineer shall calculate the system capacity and either PMV or ADPI Values for the
    it

    hottest hour of the year for the worst case for all applicable occupied spaces
    et

    2 Sport Facilities.
    m

    The Project shall also Calculate the heat loads for all critical seats for the hottest outdoor
    conditions for scheduled events.

    5.2.4 Measurement (Thermal Comfort)

    1 The Project shall complete the Thermal Comfort Calculator (Considering GSAS Assessment
    System or any other recommended system) in order to compute PMV or ADPI values and
    demonstrate that system Capacity can meet the peak cooling loads for the worst case for all
    typical occupied spaces.
    (a) System Capacity : The capacity of the system should be properly sized to meet the
    peak cooling loads of critical spaces. All projects will calculate the peak cooling loads
    for the hottest hour of the year.
    QCS 2014 Section 07 : Green Constructions Page 4
    Part 05 : Indoor Environment

    (b) PMV values: The project will evaluate all critical spaces and perform thermal comfort
    assessment for the hottest hour of the year. Calculate PMV values of different
    positions in critical spaces such as different positions relative to window and diffuser
    locations and select the worst PMV value for assessment.
    (c) ADPI values: The project will evaluate the selected worst case for each typical space
    and perform thermal comfort assessment for the hottest hour of the year in terms of
    Air Diffusion Performance Index.

    2 The following table outlines the measurement type and typical spaces used in the calculation
    according to the appropriate typology:

    Table 2: measurement type and typical spaces

    TYPOLOGY MEASUREMENT TYPE TYPICAL SPACES

    l .
    .l.
    Commercial PMV Office, Reception Areas

    rw
    Education ADPI Classrooms, Offices, Special

    ta Functional Spaces.
    qa
    Mosques ADPI Prayer Halls
    as

    Light Industry PMV Office , Operational Areas


    se

    Health Centres PMV Typical Occupied Spaces


    er
    ov

    Sports PMV or ADPI for the worest Office spaces (a),Exposed


    case Heat Load Spectator Seating (b)
    o

    *
    5.2.5 Score
    it
    et

    Note: (*) minimum QCSs requirements unless other values specified by the relevant
    authority
    m

    1 The score values for Commercial, Light Industry Typologies


    Table 3: Commercial & Light Industry Typologies

    PMV 1.5 < PMV 2.0 Under the system capacity meeting the peak load

    2 The score values for Education, Mosques Typologies


    Table 4: Education, Mosques Typologies

    ADPI 80 ADPI< 85 Under the system capacity meeting the peak load
    QCS 2014 Section 07 : Green Constructions Page 5
    Part 05 : Indoor Environment

    3 The score values for Health Centres Typology


    Table 5: Health Centers

    The Building will Comply with ASHRAE Standards- Design Manual for Hospital and Clinics

    4 The score values for Sports Typology


    Table 6: Railways Typology
    a. for office spaces (a)

    PMV 1.5 < PMV 2.0 Under the system capacity meeting the peak load

    b. for Exposed Spectator Seating (b)

    l.
    .l.
    ADPI 1.185 < b 1.600 worest case heat load

    rw
    5.3 INDOOR ENVIRONMENT [IE.2] NATURAL VENTILATION

    5.3.1 Scope ta
    qa
    1 The Indoor Environment for Natural Ventilation shall be measured for the following
    categories of the buildings.
    as

    Table 6: Building Typologies


    se

    Commercial
    Governmental
    er

    Education
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    Mosques & other religious buildings


    Light Industry
    it o

    Health Centres
    et

    Rail Buildings
    m

    Sports

    5.3.2 Description

    1 The Project shall encourage effective natural ventilation strategies in conjunction with
    mechanically ventilated systems.

    5.3.3 Measurement Principle

    1 The Engineer shall maximize the number of days that the building can utilize natural
    ventilation, either through user operable windows or through controlled opening
    QCS 2014 Section 07 : Green Constructions Page 6
    Part 05 : Indoor Environment

    5.3.4 Measurement (Natural Ventilation)

    1 All projects using operable windows will complete the Natural Ventilation Calculator to
    determine the number of months that all typical spaces can utilize natural ventilation by
    verifying minimum fresh air supply to guarantee indoor air quality as recommended in
    ASHRAE 62.1-2010. All projects using mechanical ventilation systems will demonstrate
    thorough calculation and/or simulations the number of months a project can utilize natural
    ventilation. Exclude all circulation areas from this measurement.

    2 The following table outlines the typical spaces used in the calculation according to the
    appropriate typology:
    Table 7: Typical Spaces for Natural Ventilation

    Typology Typical Spaces

    .
    M

    l
    .l.
    Commercial Office, Reception areas
    Education Classrooms, Libraries

    rw
    Mosques Prayer Halls
    Light Industry Office areas
    Health
    ta
    Staff areas, Library/Seminar rooms, Dining rooms
    qa
    Centres
    (a) LIGHT INDUSTRY
    as

    (i) Operational Areas associated with the industrial process are not included as
    part of this criterion.
    se

    (b) HEALTH CENTRES


    er

    (i) All Projects will undertake a full thermal model analysisto calculate the air flow
    provided by the natural ventilation to determine if each typical space can
    ov

    gurantee indoor air quality as recommended in ASHRAE 62.1-2010.Circulation


    areas and Clinical areas can be excluded from this calculation in line with
    guidance HTM 03-01.
    it o

    (ii) Typical Spaces to be assessed against the ASHRAE Standards include: Satff
    et

    areas , Office accommodation, Library /Seminar rooms , Dining rooms .Natural


    ventilation in accordance to ASHRAE must achieve fresh air rates of 5
    m

    l/s/person.

    5.3.5 SCORE*

    1 The recommended minimum Score for the QCS,s Targeted Typologies :


    (*) minimum QCSs requirements unless other values specified by the relevant authority

    Table 8: Commercial,Governmental,Sport, Education , Mosques,Light Industry Typologies


    Number of Months Natural Ventilation Can
    0 < months of the year 1
    be Utilized

    Table 9: For Health Centres, Rail Terminals


    The Building will Comply with ASHRAE 62.1-2010 Standards- Design Manual for Hospital
    and Clinics
    QCS 2014 Section 07 : Green Constructions Page 7
    Part 05 : Indoor Environment

    5.4 INDOOR ENVIRONMENT [IE.3] : MECHANICAL VENTILATION

    5.4.1 Scope

    1 The Indoor Environment for Mechanical Ventilation shall be measured for the following
    categories of the buildings
    Table 10: Building Typologies

    Commercial
    Governmental
    Education

    l .
    Mosques

    .l.
    Light Industry

    rw
    Health Centres
    Railways

    ta
    qa
    5.4.2 Description

    1 The Project shall provide effective mechanical ventilation to ensure occupant comfort and
    as

    health.
    se

    5.4.3 Measurement Principle


    er

    1 The Engineer shall ensure that mechanical ventilation in all primary occupancy areas meets
    the minimum requirements of ASHRAE 62.1-2010 and the system requirements in ASHRAE
    ov

    90.1-2010.

    5.4.4 Measurement (Mechanical Ventilation)


    it o

    1 The mechanical system shall meet the minimum requirements of ASHRAE 62.1-2010,
    et

    ASHRAE 90.1-2007. These requirements include, but are not limited to:
    m

    (a) Mechanical equipment must meet minimum Efficiency standards, and be properly
    verified and labeled.
    (b) Mechanical systems must have proper control systems, including the use of zoning,
    proper dead bands, off-hour controls, and automatic shut-offs.
    Note: In the Calculation of the required fresh air supply, both EN-ISO and ASHRAE should
    be used, and the larger of the two standards should be used in the verification of over
    ventilation.

    2 MEASUREMENT
    (a) LIGHT INDUSTRY
    (i) Operational Areas associated with the industrial process are not included as
    part of this criterion.
    (b) RAILWAYS
    This Criteria applies to both underground or overground stations.
    QCS 2014 Section 07 : Green Constructions Page 8
    Part 05 : Indoor Environment

    *
    5.4.5 Score (Mechanical Ventilation)

    1 The Recommended minimum Requirements by QCS as shown in (Table 11):


    Note: (*) minimum QCSs requirements unless other values specified by the relevant
    authority
    Table 11: Minimum Value
    15 % of ASHRAE 62.1-2010 requirement;
    Outdoor Air Volume (X) AND no existence of equipment with efficiency less than
    specified in ASHRAE 90.1-2010

    5.5 INDOOR ENVIRONMENT [IE.4] LOW-EMITTING MATERIALS

    5.5.1 Scope

    l .
    .l.
    1 The Indoor Environment for Low-Emitting Materials shall be measured for the following

    rw
    categories of the buildings.
    Table 12: Building Typologies

    Commercial ta
    qa
    Governmental
    Education
    as

    Mosques
    se

    Light Industry
    Health Centers
    er

    Railways
    ov

    Sports
    o

    5.5.2 Description
    it

    1 The project shall meet the minimum emissions targets for indoor materials and finishes to
    et

    ensure the comfort and health of occupants and installers.


    m

    5.5.3 Measurement Principle

    1 The Engineer shall choose materials and finishes that minimize Volatile Organic Compounds
    (VOC) emissions.

    5.5.4 Measurement (VOC)

    1 The Engineer shall complete the Low-Emitting Materials Calculator to evaluate the measured
    VOC contents of specified indoor materials.

    2 The Engineer shall develop a plan to specify materials with low VOC emission rates as found
    in the Low-Emitting Materials Calculator.
    Exclude materials used in spaces that are exposed to the exterior.
    3 RAILWAYS: This Criteria applies to both underground and overground stations.
    QCS 2014 Section 07 : Green Constructions Page 9
    Part 05 : Indoor Environment

    5.5.5 Score (VOC)

    1 Recommended minimum Requirements by QCS as shown in (table 6)


    Table 13: VOC score value

    VOCemi,total (X) 85% < X 100 %

    (*) minimum QCSs requirements unless other values specified by the relevant authority

    END OF PART

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    QCS 2014 Section 07: Green Building Page 1
    Part 06: Cultural & Economic Value

    6 Cultural & Economic value [ce] ................................................................................................ 2

    6.1 GENERAL ................................................................................................................................ 2


    6.1.1 SCOPE 2
    6.1.2 REFERENCE 2

    6.2 CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL gcc ECONOMY [ce.1] ....... 2
    6.2.1 SCOPE 2
    6.2.2 DESCRIPTION 3
    6.2.3 MEASUREMENT PRINCIPLE 3
    6.2.4 MEASUREMENT (SUPPORT OF NATIONAL GCC ECONOMY) 3
    6.2.5 SCORE 3

    6.3 CULTURAL & ECONOMIC VALUE - Heritage & Cultural Identity [ce.2] ................................ 3
    6.3.1 SCOPE 3

    .
    6.3.2 DESCRIPTION 4

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    .l.
    6.3.3 MEASUREMENT PRINCIPLE 4
    6.3.4 MEASUREMENT (HERITAGE AND CULTUAL IDENTITY ) 4

    rw
    6.3.5 SCORE 4

    ta
    qa
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    QCS 2014 Section 07: Green Building Page 2
    Part 06: Cultural & Economic Value

    6 CULTURAL & ECONOMIC VALUE [CE]

    6.1 GENERAL

    6.1.1 Scope

    1 The Cultural and Econmic Value category consists of factors associated with cultural
    conservation and support of the local economy.
    (a) Impacts: Impacts resulting from lack of cultural conservation and economic planning
    include:

    (i) Loss of Cultural Identity


    (ii) Economic stagnancy or decline

    l .
    (b) Mitigate Impact: Factors that could mitigate impact include:

    .l.
    (i) Encouraging designs to align with cultural identity and traditions

    rw
    (ii) Designing for a seamless integration into the existing cultural fabric

    (c)
    (iii)
    ta
    Planning for the use of local materials and workforce
    The recommended sub-criteria Includes:
    qa
    (i) Support of National Economy
    as

    (ii) Heritage & Cultural Identity

    6.1.2 Reference
    se

    1 The following documents are referred to in this section:


    er

    GSAS (Global Sustainability Assessment System) - v 2.1-2013, Gulf Organization for


    ov

    Research and development, Qatar (Note: QCS reference shall be limited only to this
    particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of
    o

    reference]
    it

    6.2 CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL GCC


    et

    ECONOMY [CE.1]
    m

    6.2.1 Scope

    1 The Cultural & Economic Value for Support of National Economy will be measured for the
    following categories of the buildings.
    Table 1: Building Typology
    Commercial & Governmental
    Education
    Mosques
    Light Industry
    Health Centers
    Sports
    Railways
    QCS 2014 Section 07: Green Building Page 3
    Part 06: Cultural & Economic Value

    6.2.2 Description

    1 The Project shall maximize the percentage of construction expenditures for goods and
    services originating from the national GCC economy (Gulf Cooperation Council- GCC)

    6.2.3 Measurement Principle

    1 The Engineer shall maximize the percentage of construction expenditure benefitting the
    national GCC economy.

    6.2.4 Measurement (Support of National GCC Economy)

    1 The Engineer shall complete the Support of National GCC Economy Calculator to determine
    the amount of construction expenditure benefitting the national economy, as a percentage of
    total construction costs. Construction expenditures include, but are not limited to, the

    l .
    following:

    .l.
    (a) Laborers/Contractors

    rw
    (b) Building Materials
    (c)
    (d)
    Construction Materials
    Construction Tools/Equipment ta
    qa
    (e) Temporary Facilities/Rental Spaces
    as

    2 RAILWAYS: This criteria applies to both underground and overground stations


    se

    6.2.5 Score
    er

    1 The recommended minimum score by QCS for % of Construction Expenditures Benefitting


    National Economy is as follows (Table 2).
    ov

    Table 2: Recomended Minimum Score for QCS Building Typologies


    X 30%
    o

    % of Construction Expenditures Benefitting


    National Economy (X)
    it
    et

    6.3 CULTURAL & ECONOMIC VALUE - HERITAGE & CULTURAL IDENTITY


    m

    [CE.2]

    6.3.1 Scope

    1 The Cultural & Economic Value for Heritage and Cultural Identity shall be measured for the
    following categories of the buildings.
    Table 3: Building Typologies
    Commercial
    Governmental
    Education
    Mosques
    Health Centers
    Sports
    Railways
    QCS 2014 Section 07: Green Building Page 4
    Part 06: Cultural & Economic Value

    6.3.2 Description

    1 The Project shall encourage design expression that will align with and strengthen cultural
    identity and traditions.

    6.3.3 Measurement Principle

    1 The Engineer shall develop a concept brief outlining design strategies. The Qatar Heritage
    organization and/or an independent expert panel assigned by the Certification Authority will
    assess the design and determine whether the project meets the goals outlined in the mission
    statement.

    6.3.4 Measurement (Heritage and Cultual Identity )

    1 All projects shall develop a concept brief to demonstrate the following through drawings and

    l.
    descriptions of the design strategy:

    .l.
    (a) Enhancement, strengthening and reflection of cultural identity and traditions

    rw
    (b) Harmonization with cultural values of the region
    The compliance range will be defined by an Expert Heritage Panel assigned by the
    Certification Authority
    ta
    qa
    2 RAILWAYS: This criteria applies to both underground and overground stations
    as

    6.3.5 Score
    Table 4: Recomended Minimum Score for QCS Building Typologies
    se

    To be defined by Certification Authority


    er
    ov

    END OF PART
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    QCS 2014 Section 07: Green Constructions Page 1
    Part 07: Management & Operations

    7 MANAGEMENT & OPERATION [MO] ..................................................................................... 2

    7.1 GENERAL ................................................................................................................................ 2


    7.1.1 SCOPE 2
    7.1.2 REFERENCE 2

    7.2 MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT .............................. 3


    7.2.1 SCOPE 3
    7.2.2 DESCRIPTION 3
    7.2.3 MEASUREMENT PRINCIPLE 3
    7.2.4 SCORE 3

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 07: Management & Operations

    7 MANAGEMENT & OPERATION [MO]

    7.1 GENERAL

    7.1.1 Scope

    1 The Management and Operations Category consists of factors associated with building
    design management and operations
    (a) Impacts: Environmental impacts resulting from ineffective building management and
    operations include:

    (i) Climate Change


    (ii) Fossil Fuel Depletion

    l .
    (iii) Water Depletion

    .l.
    (iv) Materials Depletion

    rw
    (v) Land use and Contamination
    (vi)
    (vii)
    Water Pollution
    Air Pollution ta
    qa
    (viii) Human Comfort & Health
    as

    (b) Mitigate Impact: Factors that could mitigate impact include:


    (i) Creating a Commissioning plan to meet all the sustainable goals of the project
    se

    (ii) Providing facilities for the collection ,storage ,and proper removal of organic
    waste
    er

    (iii) Providing facilities for the collection ,storage ,and proper removal of recyclables
    ov

    (iv) Providing leak detection systems


    o

    (v) Providing energy and water use sub-metering systems


    it

    (vi) Providing an automated building control system to optimize building


    et

    performance
    m

    (vii) Managing hospitality resources to reduce waste and support sustainable food
    sources
    (viii) Promote and educate users about the sustainable initiatives of the building
    (ix) Providing a beneficial legacy to the community

    7.1.2 Reference

    1 The following documents are referred to in this section:


    Global Sustainability Assessment System (GSAS) - v 2.1-2013, Gulf Organization for
    Research and development, Qatar (Note: QCS reference shall be limited only to this
    particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of
    reference]
    QCS 2014 Section 07: Green Constructions Page 3
    Part 07: Management & Operations

    7.2 MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT

    7.2.1 Scope

    1 Recycling Management shall be measured for the following categories of the buildings:
    Table1: Building Typology
    Commercial
    Governmental
    Education
    Light Industry
    Health Centers
    Sports

    l .
    .l.
    Railways

    rw
    7.2.2 Description

    1 The Project shall encourage space planning to designate containment facilities for the
    ta
    buildings recyclable waste streams in order to minimize waste taken to landfills or
    qa
    incineration facilities.

    7.2.3 Measurement Principle


    as

    1 The Project shall develop and implement a Recycling Mangement Plan for the collection,
    se

    storage, and removal of recycling.Measurement


    er

    2 The Engineer shall demonstrate that a central sorting and storage area is located close to a
    truck loading area, and that sufficient storage has been provided for the recyclable material
    ov

    produced. The sorting and storage area must be properly isolated and ventilated to reduce
    negative health impacts for users and visitors on the site. Outline the collection procedures
    o

    for recyclable materials in the project to demonstrate that recyclable materials will be easily
    it

    collected and sorted. The Engineer shall also demonstrate how recyclable materials will be
    et

    handled at an off-site facility.


    m

    7.2.4 Score
    Table 2: Recommended minimum Requirement for QCSs Building Typologyies

    Recycling Mangement Plan Shall demonstrate Compliance

    End of Part
    QCS 2014 Section 07: Green Constructions Page 1
    Part 08: Materials

    8 MATERIALS [M] ....................................................................................................................... 2


    8.1.1 SCOPE 2
    8.1.2 REFERENCE 2
    8.2.1 SCOPE 2
    8.2.2 DESCRIPTION 3
    8.2.3 MEASUREMENT PRINCIPLE 3
    8.2.4 MEASUREMENT 3
    8.2.5 SCORE 3

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    QCS 2014 Section 07: Green Constructions Page 2
    Part 08: Materials

    8 MATERIALS [M]

    8.1 GENERAL

    8.1.1 Scope

    1 The Material category consists of factors associated with material extraction, processing,
    manufacturing, distribution, use/reuse, and disposal.
    (a) Impacts: Environmental impacts resulting from material use and unsustainable
    practices include:
    (i) Material depletion
    (ii) Climate Change

    l .
    (iii) Fossil Fuel Depletion

    .l.
    (iv) Air Pollution

    rw
    (b) Mitigate Impact: Factors that could mitigate environmental impact due to material use
    include:
    (i) ta
    Using local Materials to reduce transportation needs
    qa
    (ii) Using responsibly sourced materials
    (iii) Using materials with high recycled contents
    as

    (iv) Recycling and Reusing materials, on-and off-site


    se

    (v) Reusing structural elements, on-and off-site


    er

    (vi) Designing for ease of disassembly and reuse/recycling


    ov

    8.1.2 Reference

    1 The following documents are referred to in this section:


    o

    Global Sustainability Assessment System (GSAS) - V2.1 2013, Gulf Organization for
    it
    et

    Research and Development, Qatar (Note: QCS reference shall be limited only to this
    particular version of GSAS and non-other),
    m

    8.2 MATERIALS [M.1] REGIONAL MATERIALS

    8.2.1 Scope

    1 The Regional Materials shall be measured for the following categories of the buildings
    Table 1: Building Typology
    Commercial
    Governmental
    Education
    Mosques
    Light Industry
    Health Centres
    Sports
    Railways
    QCS 2014 Section 07: Green Constructions Page 3
    Part 08: Materials

    8.2.2 Description

    1 Encourage the use of regionally manufactured and assembled building elements and
    materials in order to reduce the carbon footprint of the materials

    8.2.3 Measurement Principle

    1 All projects shall use materials that are regionally manufactured and assembled

    8.2.4 Measurement

    1 All projects shall complete the Regional Materials Calculator to compute a Performance
    Indicator based on the weight and sourcing distance of all applicable materials. Materials
    sourcing distance can either be regional (less than or equal to 200 kilometres) or external
    (over 200 kilometres). All projects will only consider materials permanently installed in the

    l .
    project. Exclude mechanical, electrical, and plumbing assemblies, as well as specialty items

    .l.
    and equipment.

    rw
    8.2.5 Score

    ta
    Table 2: Recommended minimum Score for QCSs Building Typologies
    qa
    Performance Indicator (X) 20 X 30
    as

    END OF PART
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    QCS 2014 Section 08: Drainage Works Page 1
    Part 01: General

    1 GENERAL ............................................................................................................... 2
    1.1 SUMMARY .............................................................................................................. 2
    1.1.1 Scope 2
    1.1.2 References 2
    1.1.3 Definitions 2
    1.1.4 System Description 3
    1.1.5 Submittals 3
    1.1.6 Quality Assurance 5
    1.1.7 Site in Private Lands 5
    1.1.8 Inspection and Handover Procedure 5
    1.2 TESTING OF MATERIALS ...................................................................................... 5
    1.2.1 Materials Generally 5

    .
    1.2.2 100 Day Acid Test 6

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    .l.
    1.3 IMPLEMENTATION ................................................................................................. 7

    rw
    1.3.1 Site Information 7
    1.3.2 Health and Safety 7
    1.3.3 Setting Out of the Works 10
    1.3.4 Inspection of Works ta 10
    qa
    1.3.5 CCTV Survey 11
    1.3.6 Compensation for Damage to Property 12
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    QCS 2014 Section 08: Drainage Works Page 2
    Part 01: General

    1 GENERAL

    1.1 SUMMARY

    1.1.1 Scope

    1 This Section includes specifications for the construction and rehabilitation of sewerage,
    surface water drainage and treated sewage effluent pipelines, piping, pipeline appurtenances
    and sewage treatment plants.

    2 This Part includes general requirements basic to this Section and common to its Parts.

    3 Related Parts and Sections are as follows:

    .
    This Section

    l
    .l.
    Part 10, Pipeline Cleaning and Inspection Survey

    rw
    Section 1, General
    Section 5, Concrete
    Section 6, Roadworks
    Section 9, Mechanical and Electrical Equipment ta
    qa
    Section 10, Instrumentation, Control and Automation
    Section 21, Electrical Works.
    as

    1.1.2 References
    se

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


    er

    American National Standards Institute, ANSI


    American Society for Testing and Materials, ASTM
    ov

    American Water Works Association, AWWA


    British Standards Institution, BS
    Euro Norms, EN
    o

    Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance Section
    it

    National Joint Health and Safety Committee for the Water Services, UK
    et

    International Organization for Standardization, ISO


    m

    Swedish Standards Commission, SS


    Water Research Centre, WRC, UK

    2 The following standards or revised/updated versions and other documents are referred to in
    this Part:
    BS 6100 ......................Glossary of building and civil engineering terms
    BS 8010 ......................Pipelines
    BS EN 752 ..................Drain and Sewer Systems outside buildings

    1.1.3 Definitions

    1 The following definitions apply generally to this Section. These and other definitions included
    in this Section are based, where applicable, on BS 6100, Part 2.

    (a) Surface water: Water that flows over, or rests on, the surface of buildings, other
    structures or the ground; the definition is extended to include groundwater.
    QCS 2014 Section 08: Drainage Works Page 3
    Part 01: General

    (b) Sewage: Contents of a sewer that does not solely convey surface water.
    (c) Treated sewage effluent (TSE): Effluent from a sewage treatment works following
    completion of treatment of sewage and disinfection of the treated sewage effluent to
    attain a water quality standard suitable for reuse for selected purposes.

    1.1.4 System Description

    1 Unless otherwise specified herein or elsewhere in the Specification, designated in the Project
    Specification, or directed by the Engineer, the material, equipment and systems to be
    provided under this Section shall:

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


    (i) under the climatic conditions in Qatar as stated in Section 1
    (ii) in handling the process fluids and materials of the prevailing and indicated

    l .
    .l.
    (iii) quality and quantity and variations thereof

    rw
    (iv) under the prevailing and indicated characteristics and quality of the natural and
    (v) process environments and process materials
    (b)
    ta
    comply with the provisions of BS EN 752, BS 8010, and BS 8301.
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    1.1.5 Submittals
    General
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    1 The Contractor shall submit to the Engineer for approval all drawings and data including
    samples, calculations, schedules, certificates and other submittals specified in Section 1, this
    se

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


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


    it
    et

    3 During the course of the Works, the Contractor shall maintain a detailed record of all
    changes in order to facilitate accurate preparation of record drawings and to ensure that
    m

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

    4 The Contractor shall provide the Engineer or his nominated representative drawings and a
    photocopy of each schedule correctly and neatly modified in red ink to truly represent the
    Works constructed. These shall be submitted to the Engineer or his nominated
    representative for approval before the contract completion date.

    5 If any drawing is not approved, it shall be returned to the Contractor with marked indications
    of the additional information required.

    6 In addition the Contractor shall complete the Drainage Affairs Network Record Sheets in the
    prescribed format but not necessarily limited to, the following Record Sheets as applicable in
    both hard copy and electronic copy in a widely used Data Exchange Format (DXF) textual
    (i.e. .mdb, .xls or similar approved) format. Electronic format record sheets shall be obtained
    from the Engineer or his nominated representative.
    QCS 2014 Section 08: Drainage Works Page 4
    Part 01: General

    PIPE LINE AND APPURTENANCES PUMPING STATIONS


    a) Manhole Record (2 pages) a) Pumping Station Well Inventory Sheet

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


    pages)
    c) Sewer Record c) Pumping Station Motor Inventory Sheet

    d) Valve Inventory d) Pumping Station Penstock Inventory Sheet

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

    f) TSE Pipeline Record f) Pumping Station Pump Inventory Sheet

    g) Rising Main Record g) Pumping Station Shaft Inventory Sheet

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

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    i) TSE Distribution Chamber i) Pumping Station Ventilation Inventory Sheet

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    j) Overflow Pipe Record j) Pumping Station Fan Inventory Sheet

    k) TSE/Rising Main Fittings Record k) Pumping Station Generator Sheet

    l) House Connection Record l) ta


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


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


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    7 The Contractor shall be deemed to have included all provisions within his Tender should the
    above list be altered by PWA from time to time.
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    8 Individual Record Sheets shall be prepared for each length of sewer, TSE pipeline, rising
    it

    main and overflow pipe, each manhole and house and gully connection, and shall be
    et

    submitted to the Engineer or his nominated representative for approval after which they shall
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    become the property of the Employer.

    9 Record sheets for pipelines (c, f, g, i, j, k, l & n above as appropriate), and record sheets for
    any other work that is to be covered up, shall be presented for approval prior to covering up
    the works. Backfilling will not be permitted prior to the record sheets being approved.

    10 Record sheets for work of an exposed nature that can be later verified by the Engineer or his
    nominated representative may be submitted up to 14 days after the work has been carried
    out.

    11 Photocopies of record sheets relating to work carried out since the previous valuation shall
    be submitted with each interim valuation application.

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


    sheets for the work in question.
    QCS 2014 Section 08: Drainage Works Page 5
    Part 01: General

    13 A Certificate of Completion will not be issued until a complete set of Record Sheets endorsed
    by the Engineers Site Representative has been presented to the Engineer.

    14 Blank hard copy Record Sheets, as detailed in sub-clause 6 above will be supplied by the
    Engineer.

    15 The Contractor shall accurately locate by co-ordinates to the Qatar National Grid, the centre
    of all covers of manholes and chambers constructed under this project or to which any work
    whatsoever has been undertaken under this project. The Contractor shall also locate by co-
    ordinates the position of buried bends and fittings on pressure mains. Where pipelines are
    not laid to straight lines between chambers or fittings the co-ordinates of every pipe joint shall
    be recorded prior to covering up the pipeline. Where flexible pipes are used coordinates
    shall be at 10m intervals.

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

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    1.1.6 Quality Assurance

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    1 Materials and products shall be furnished by approved suppliers as designated in the
    Contract and Project Specifications.

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    Survey work for obtaining record sheet data and the compilation of the data shall be carried
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    out by approved prequalified surveying companies designated in the Contract or Project
    Specification.
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    1.1.7 Site in Private Lands


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


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    1 The inspection and handing over of the Works to the Employer shall be in accordance with
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    the procedure specified in Section 1, and, Clauses 1.3.4 and 1.3.5 of this Part.

    1.2 TESTING OF MATERIALS

    1.2.1 Materials Generally

    1 All materials to be used in contact with sewage or its atmosphere must be shown to
    withstand corrosion. In the absence of satisfactory evidence of equivalent testing results,
    materials will be required to pass the 100 day acid test as detailed in Clause 1.2.2 of this
    Part.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 01: General

    1.2.2 100 Day Acid Test


    General
    1 Based on the results at 100 days, materials shall be deemed to be unsuitable for use in
    contact with sewage or sewer atmosphere in the opinion of the Engineer the tested samples
    fail to satisfy any of the following requirements:

    2 All materials to be used in contact with sewage or its atmosphere must be shown to
    withstand corrosion and in the absence of satisfactory evidence of equivalent testing results
    will be required to pass successfully the 100 day acid test as detailed in this Specification.
    The test shall be carried out by an approved laboratory, experienced in undertaking the test.

    3 All materials to be used in contact with sewage or its atmosphere must be shown to
    withstand corrosion. Such materials may be divided into two categories:

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    4 Category 1 Materials - material which serve a purpose other than protection (e.g. pipes and

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    pipe jointing materials)

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    5 Category 2 Materials materials which protect other (usually structural) corrodible materials
    (e.g. coating to step irons, GRP manhole liners, acid resistant mortar).

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    Sample preparation and testing shall, as far as is possible, simulate the conditions to which
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    the materials will ultimately be subjected.
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    7 Samples shall be taken and prepared in a manner to be approved by the Engineer. Care
    shall be taken in preparation of samples of non-homogenous materials to ensure that only
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    the face that will be exposed to the corrosive environment in the sewer is exposed to the acid
    during the testing.
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    (a) Samples in Category I materials shall be cut from pipe/pipe joint samples selected by
    the Engineer and cut ends adequately protected by a gel coat.
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    (b) Samples of Category II materials shall be generally prepared by coating a corrodible


    material with the protective coating to be tested.
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    8 For each test two samples shall be prepared and indelibly marked with an identifying number.
    et

    9 One sample shall be partially immersed in 10% V/V sulphuric acid maintained at a
    m


    temperature of 50 C for 100 days. The concentration of acid shall be maintained by
    preventing evaporation. In addition the strength of the acid shall be regularly checked and
    the level and strength adjusted as necessary. The second sample shall be kept as a control.

    10 The test sample shall be visually inspected at weekly intervals. Interim reports on the
    condition of the sample shall be submitted to the Engineer by the laboratory following visual
    inspections of the samples after 25, 50 and 75 days. Such reports shall include reference to
    any changes in surface condition and colour of the samples, changes in colour of the liquid,
    and any presence of any particles in the liquid.

    11 If the interim report after 75 days is satisfactory the Contractor may request the Engineers
    approval to use of the material prior to completion of the 100 day acid test. Such approval
    shall be solely at the discretion of the Engineer, and the use of the materials shall be entirely
    at the Contractors risk. Any costs associated with the replacement of such materials, should
    they subsequently fail the acid test, shall be borne by the Contractor.
    QCS 2014 Section 08: Drainage Works Page 7
    Part 01: General

    12 On completion of the test period, the sample tested in sulphuric acid shall be split or the
    coating removed to determine the internal condition of the sample. The final test report shall
    give full details of:

    (a) The test procedure adopted.


    (b) The surface condition of the samples before, during and after testing, listing the times
    at which significant changes in appearance were noted.
    (c) The internal condition of the sample.
    (d) Any changes in the solution.

    13 Materials shall be deemed to be unsuitable for use in acid environments if the acid tested
    samples fail to satisfy any of the following requirements:

    (a) Category 1 Materials - the surface of the samples shall not be significantly different in

    .
    texture from the non-immersed control sample.

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    (b) Category 2 Materials -the underlying corrodible material shall not show any sign of

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    corrosion.

    14 The surfaces of the samples shall not be significantly different in texture from the non-

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    immersed control sample. No change in surface hardness will be permitted, and no splits,
    cracks, blisters or delamination will be allowed.
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    1.3 IMPLEMENTATION
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    1.3.1 Site Information


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


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    or furnished by the Engineer, the Contractor shall be responsible for obtaining his own
    information on ground and subsoil conditions at the Site and the locations of all pipelines and
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    services within or near the Site.

    2 The Contractor shall complete a services information sheet for each section of the Works
    o

    and shall submit the completed sheet for the Engineers approval at least seven days before
    it

    work is due to begin on that section. Work shall not begin on that section until the respective
    et

    services information sheet has been approved by the Engineer.


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

    1.3.2 Health and Safety

    1 The requirements of this Clause are pursuant to or in addition to the health and safety
    requirements in Section 1 and Section 11. Safety requirements in relation to specific classes
    of work are specified in other Parts of this Section.

    2 The recommendations contained in Working with Sewage The Health Hazards Pbulished
    by the Health & Safety Executive http://www.hse.gov.uk/pubns/indg198.htm shall be
    adhered to in respect of all work to be carried out in operational sewers, pumping stations
    and sewage treatment works.
    QCS 2014 Section 08: Drainage Works Page 8
    Part 01: General

    3 Arrangements shall be made with Drainage Operation and Maintenance Department, Public
    Works Authority before entering in or working on existing sewers and associated works. A
    Permit to Work must be obtained from Asset Affairs Drainage Operations and Maintenance
    Department prior to any works taking place .

    4 The Contractors attention is drawn to the hazards involved in working in confined spaces
    including sewers, manholes, inspection chambers, wet wells, pumping stations and ancillary
    structures. The Contractor shall be responsible for ensuring that adequate precautions are
    taken to ensure safe working conditions as well as the availability of safe tools and facilities.
    The Contractor shall issue his risk assessment to the Engineer for his approval prior to
    applying for a Permit to Work at the site. This risk assessment shall meet but not be limited
    to the requirements of this Part of this Section.

    5 The Contractor shall appoint a Safety Officer who shall be suitably qualified and experienced.
    The Contractor shall ensure that the Safety Officer is available on Site during the mobilisation

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    period and thereafter to train the Contractors personnel in safety operations. The work shall

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    not proceed unless such training has been accomplished to the Engineers approval.

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    6 The Safety Officers main responsibilities shall be to

    (a)
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    ensure that all the Contractors employees follow the agreed safety procedures
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    (b) ensure that all employees are supplied with the appropriate safety/protective
    equipment and that it is used and maintained as per agreed procedures
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    (c) assist in carrying out of refresher safety training courses for working in confined
    spaces
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    (d) investigate all accidents and dangerous occurrences, and where applicable, submit
    reports recommending actions to be taken to prevent a recurrence.
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    7 The Contractor shall provide and erect approved safety barriers around all unattended open
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    manholes and trenches. All manholes shall be covered with suitable temporary steel sheets.
    Advance warning notice road signs shall be erected at least 50 m either side of areas where
    work is in progress.
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    8 The need for adequate protection to the general public in the vicinity of the Works is
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    stressed.
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    9 Care must be exercised when working in or near live sewers, and tests must be made to
    verify that no hydrogen sulphide or other toxic gases are present, before anyone enters an
    existing manhole or confined space.

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


    working in, or near, or inspecting pipelines, manholes, chambers, treatment units, pumping
    stations, or any confined space. In this connection the Contractor must obtain appropriate
    safety equipment and acquaint all personnel with the dangers involved, and precautions to be
    taken, and shall regularly discuss with the Engineer's Representative the sufficiency of safety
    precautions on site.

    11 The following minimum precautions must be taken before entry into a manhole, chamber or
    other confined space:

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


    the entry point shall be removed to ensure adequate ventilation.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 01: General

    (b) The manhole or confined space must be thoroughly ventilated by mechanical air
    blower prior to entry.
    (c) Before entering the confined space the atmosphere shall be checked for the presence
    of toxic gases, flammable gases, and oxygen level.
    (d) The mechanical air blower must be kept close by the manhole or confined space that
    has been entered.
    (e) No naked lights, matches or lighters shall be used in a sewer or in close proximity to
    an open manhole or chamber. All equipment shall be intrinsically safe.
    (f) The hydrogen sulphide level in the manhole or confined space must be continually
    monitored. If the level rises the manhole or confined space must be evacuated
    immediately.
    (g) All persons entering a manhole or confined space must wear a safety harness properly

    .
    rigged to the lifting frame.

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    (h) At least two top men must be available to operate the air blower and lifting tackle in the

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    event of an emergency. The top men shall keep in touch with the men in the sewer,
    manhole, chamber or confined space by calling or signalling to them at frequent
    intervals. No person shall enter the confined space alone.

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    Before entering any confined space, the atmosphere shall be checked for the presence of
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    toxic gases, flammable gases and oxygen level. The Contractor shall have on site in working
    order, sufficient calibrated gas monitors to continually monitor the atmosphere in all confined
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    spaces and in all areas adjacent to sewage where men are working.

    13 The Contractor will not be permitted to work in manholes, pipelines, or pumping stations if
    se

    such gas monitors are not in use.


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    14 The following equipment is to be made available throughout the Contract at each and every
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    entry point to a confined space.


    Safety Harness (not a safety belt) and ropes 1 No.
    Lifting frame and tackle for safety harness 1 No.
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    Gas monitor 1 No.


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    Mechanical air blower with compressor and generator 1 No.


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    15 Gas monitors shall incorporate the following features:

    (a) (a) Continuous monitoring of oxygen level, with visual and audible high and low level
    alarms.
    (b) (b) Continuous electrochemical monitoring of Hydrogen Sulphide with indication of the
    gas concentration, and audible and visual alarms under the following conditions:
    (i) Time weighted average providing 8 hours exposure at the threshold limit value.
    (ii) Time weighted average providing 10 minutes of exposure at short term
    exposure limit, or ceiling value.
    (iii) Exposures to ten times the threshold limit value.
    (c) (c) Continual monitoring for flammable gas at intervals not exceeding 2 minutes.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 01: General

    1.3.3 Setting Out of the Works

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


    The Contractor shall locate, by co-ordinates to the Qatar National Grid, the locations of the
    elements of the Works. Pipelines shall be located by the position of the centre of manholes
    and chamber covers. Pressure pipelines shall be located by the position of bends and fittings.

    2 The execution of surveys, recording of data and preparation of record sheets shall comply
    with the following requirements:

    (a) surveys shall be based on Qatar National Grid survey control points
    (b) co-ordinates shall be located to within 0.1 m
    (c) co-ordinates shall be determined by radial (polar) observations using theodolite and
    electronic distance measuring (EDM) equipment. The co-ordinates shall be checked

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    by independent methods and the error shown to be within acceptable limits

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    (d) if required, additional temporary control points may be established as follows:

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    (i) observations for additional temporary control points shall consist of at least two
    (ii) rounds of angles (on two faces) with a different zero setting for each round.
    (iii) ta
    where applicable, distances shall be determined by trigonometric methods and
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    (iv) at least two rounds of vertical angles (on two faces) shall be observed.
    (v) positions of additional temporary control points shall be determined by
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    (vi) reference to not less than three Qatar National Grid survey control points and
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    shall be proven to have standard errors of not more than 0.08 m.


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


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    documentation used in determining the co-ordinates shall be submitted to the Engineer. A


    daily log giving the number of additional control stations and manholes surveyed shall be
    maintained and submitted. A comprehensive report on the work carried out including
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    methods used, problems encountered, solutions used and a full summary of the results shall
    it

    be submitted.
    et

    4 The Engineers approval of the setting out shall be obtained before work on each element
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    commences.

    5 The Contractor shall be deemed to have included all provisions within his tender for the
    topographical survey information which should include: - features (fittings), manhole
    chamber co-ordinates/levels in a widely used Data Exchange Format (DXF), accurate
    positional survey drawings (i.e. either.DWG or.DXF) layout files together with equally widely
    used DXF textural (i.e. xls, .txt or similar approved).

    1.3.4 Inspection of Works

    1 The Contractor shall provide a safe and convenient means of access to the Works to enable
    the Engineers inspections to be carried out.

    2 The Contractor shall submit to the Engineer notice of work requiring inspection on a
    completed Notice of Inspection Required form not less than 24 hours before requiring
    inspection of those works. Blank forms will be provided by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 01: General

    3 Requests for inspection by the Engineer shall be submitted for the following:

    (a) setting out


    (b) formation level of excavation
    (c) pipelaying, bedding and testing
    (d) base slabs
    (e) manhole precast chamber rings in place before internal linings and external coatings
    are applied
    (f) manhole concrete surround
    (g) formwork and reinforcing steel before concreting
    (h) before backfilling of permanent Works

    .
    (i) before reinstatement

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    (j) any other constructional operation that the Engineer may require.

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    4 Works covered up or in any way made unavailable for inspection before the submission of
    the Notice of Inspection Required form or the Engineers approval to proceed shall be
    uncovered at the Contractors expense.
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    5 Prior to inspection, the Contractor shall submit his Quality Control plan (QC plan) / Inspection
    and Test Plan (ITP) in accordance with Section 1 Clause 7.6.3.
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    1.3.5 CCTV Survey


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    1 The Contractor shall on written instruction of the Engineer undertake a CCTV survey on
    designated lengths of pipelines laid during the execution of the Works, including pipeline
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    cleaning where necessary and submission of a Survey Report, as part of the final inspection
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    of the Works.

    2 The Certificate of Completion for the Works or part thereof shall not be issued until the CCTV
    o

    Survey, including provision of the Survey Report, and any subsequent sewer remedial works
    it

    have been completed to the satisfaction of the Engineer.


    et

    3 Should any length of the surveyed between adjacent manholes, or the manholes indicate
    m

    failure to comply with the requirements of the Contract, the whole cost of any pipeline
    cleaning, the CCTV Survey, Survey Report and any subsequent remedial works carried out
    to the satisfaction of the Engineer shall be borne by the Contractor.

    4 The CCTV Survey shall be carried out by an approved specialist subcontractor designated in
    the Project Specification. The subcontractor shall provide suitable documentation to verify
    previous experience in undertaking CCTV Surveys to the satisfaction of the Engineer.

    5 Pipeline cleaning and CCTV surveys and reporting shall be carried out as specified in Part 10
    of this Section.
    QCS 2014 Section 08: Drainage Works Page 12
    Part 01: General

    1.3.6 Compensation for Damage to Property

    1 Before commencing any work on site, the Contractor shall undertake an extensive condition
    survey of all properties adjacent to the proposed works. A detailed report including sketch
    plans, schedules of defects and photographs shall be submitted to the Engineer for
    agreement.

    2 The Contractor shall not mark boundary walls to properties in any way whether deliberately
    for identification purposes or accidentally. All markings, howsoever caused, shall be repaired
    and repainted. Sufficient area of wall shall be repainted to avoid a patchy appearance.

    END OF PART

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    QCS 2014 Section 08: Drainage Works Page 1
    Part 10: Pipeline Cleaning and Inspection Survey

    10 PIPELINE CLEANING AND INSPECTION SURVEY .................................... 2

    10.1 GENERAL ...................................................................................................... 2


    10.1.1 Scope 2
    10.1.2 References 2
    10.1.3 Submittals 2
    10.1.4 Specialist Subcontractor 3
    10.1.5 Programme of Work 3
    10.1.6 Topographic Survey of Sewers 4
    10.1.7 Safety Requirements 4
    10.2 SEWER CLEANING ...................................................................................... 6
    10.2.1 Scope 6

    .
    10.2.2 Cleaning of Sewer Pipelines 7

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    10.2.3 Jetting 8

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    10.2.4 Winching 9
    10.2.5 Bucketing 9
    10.2.6 Balling or Kiting and Pipeline Internal Gauging 9
    10.2.7 General Cleanliness of Areas during Sewer Cleaning
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    10.3 SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING .......... 10
    10.3.1 Scope of Work 10
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    10.3.2 Survey Requirements 10


    10.3.3 Survey Equipment 11
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    10.3.4 Survey Vehicle 13


    10.3.5 Photographs 14
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    10.3.6 Site Coding Sheets 14


    10.3.7 Excavation 15
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    10.3.8 Survey Reporting 15


    10.4 OVERPUMPING AND FLOW DIVERSION ................................................. 16
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    10.4.1 Source of Flow 16


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    10.4.2 Pipe Stoppers 17


    10.4.3 Stopping Off Flow 17
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    10.4.4 Pumping Plant 17


    10.4.5 Sewage Flooding 17
    10.4.6 Overpumping of Flow 18
    10.4.7 Temporary Diversion of Flow 18
    10.4.8 Entrances to Private Properties 18
    10.4.9 Odour and Noise Control During Flow Diversion and Overpumping 18
    10.5 CONTRACTORS QUALITY CONTROL PROCEDURE .............................. 18
    QCS 2014 Section 08: Drainage Works Page 2
    Part 10: Pipeline Cleaning and Inspection Survey

    10 PIPELINE CLEANING AND INSPECTION SURVEY


    10.1 GENERAL

    10.1.1 Scope

    1 This Part includes the specification for all work necessary to clean and carry out inspection
    surveys of sewerage pipelines. The specification applies equally to the cleaning and
    inspection survey of surface water and ground water pipelines.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, General
    Part 2, Earthworks

    .
    Part 4, Pipe Installation

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    Part 11, Sewer Rehabilitation

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    Section 1, General.

    10.1.2 References
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    1 The following document is referred to in this Part:
    Water Research Centre (WRC) Manual of Sewer Condition Classification
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    Water Research Centre (WRC) Sewer Rehabilitation Manual


    10.1.3 Submittals
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    1 The Contractor shall submit complete data and details for pipelines cleaning and inspection
    survey for the Engineers approval as follows:
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    (a) programme of work, detailed method statement, and schedule of equipment to be


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    used on the project, general plant and specialist equipment


    (b) proposed methods of flow diversion and overpumping
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    (c) specific data for the proposed specialist equipment before beginning any sewer
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    cleaning and inspection as follows:


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    (i) original catalogues for all the proposed specialist equipment, which complying
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    with the Specifications. These catalogues shall be considered as an integral


    part of the Contractors method statement. All equipment to be provided for
    sewer cleaning and closed circuit television (CCTV) survey and sonar scanning
    shall be reliable and in good working condition
    (ii) typical video recordings preferably on CD ROM of similar work carried out
    previously by CCTV camera and sonar scanner. Such recordings, if acceptable,
    will be retained by the Engineer as the standard for appraisal of subsequent
    recordings
    (iii) video graphic printer
    (iv) still pictures in digital format (Tiff, JPEG) for computer data storage and
    retrieving

    (d) specific data to be submitted while carrying out and at the completion of the work:
    (i) site coding sheets as designated under Clause 10.3.6 in this Part
    QCS 2014 Section 08: Drainage Works Page 3
    Part 10: Pipeline Cleaning and Inspection Survey

    (ii) the master and a copy of each video recording as designated in Clause 10.3.2 in
    this Part
    (iii) still colour pictures using video graphic printer of the inside of sewers,
    manholes, inspection chambers, and grease and oil interceptors, and the
    interior of pumping stations as required and as specified in Clause 10.3.5 of
    this Part.

    2 The Contractor shall submit a method statement to the Engineer for approval four weeks in
    advance of commencing activity on site. The method statement shall comprise but not
    necessarily be limited to:

    (a) Equipment set-up and locations of proposed access points


    (b) Anticipated cut off periods for services
    (c) Procedures for notifying affected residences and businesses
    (d) Procedures for verification of active services

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    (e) Procedures for complying with traffic control
    (f) Procedures for seeking permits to work.

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    (g) Safety procedures in particular working with scaffolding and entering confined spaces.

    10.1.4 Specialist Subcontractor


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    1 The Contractor shall employ an approved specialist subcontractor designated in the contract
    document.
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    2 The Contractor shall provide the following information on sewer cleaning and inspection
    survey contracts carried out by the proposed subcontractor during the last five years:
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    (a) project location


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    (b) name and address of client


    (c) start and completion dates
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    (d) cost of the works undertaken by the subcontractor


    (e) length, diameter and material of sewers
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    (f) reference letter from the client or engineer


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    et

    (g) a sample document of the reports produced for at least two projects.
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    3 All operators employed by the subcontractor shall be fully skilled in the specified works.

    4 The operator for interpreting the video recordings and preparing the site coding sheets shall
    be fully conversant with picture interpretation, defect coding and classification. A copy of the
    operators current certificate of qualification for sewer surveys and fault classification issued
    by Water Training International of the U.K. or an equivalent body for the types of sewers to be
    inspected shall be submitted to the Engineer for approval before beginning the survey. If the
    Engineer determines that the Operators qualifications and experience are not acceptable,
    the Contractor shall provide an acceptable replacement before beginning the survey.

    10.1.5 Programme of Work

    1 The sewage pipelines may be frequently surcharged and ready access to them may not be
    available. The Contractor shall make due allowance for such disruptions in his programming
    of operations. The Contractor shall cause minimum disruption to the utilisation of the
    pipelines and the period of overpumping shall be kept to the minimum necessary. Before
    starting the cleaning and inspection survey in any sewer length, the Contractor shall submit
    an applications to CED Drainage Division O & M Section for a permit to work in the sewers.
    QCS 2014 Section 08: Drainage Works Page 4
    Part 10: Pipeline Cleaning and Inspection Survey

    10.1.6 Topographic Survey of Sewers

    1 A topographic survey of the pipelines to be cleaned shall be carried out by the Contractor and
    a schedule provided to the Engineer. Some manhole covers may be buried under
    landscaping, debris, or the surface of roads, footpaths, or other pavements. These manholes
    shall be located by the Contractor on the basis of the Employers record drawings using
    appropriate techniques and apparatus. The topographic survey of the sewer system shall
    include resurveying where affected by any rehabilitation works on completion of the sewer
    cleaning and inspection surveys as directed by the Engineer.

    2 The survey shall include details of manholes, chambers, and oil and grease interceptors
    including topographic levels of covers and inverts, locations and co-ordinates.

    3 The Contractor shall locate accurately and survey all junctions and lateral connections into
    manholes, or directly into sewers, whether or not the existence or location of such junctions
    and lateral connections are shown on the Employers record drawings.

    l .
    .l.
    4 The Contractor shall survey the original ground surface, taking levels at 50 m intervals or as
    directed by the Engineer along the route of the sewer, determine existing pipe diameters and

    rw
    invert levels, and the details shall be recorded in a schedule to the Engineers approval.
    These details shall, when finally and mutually agreed, be signed by the Contractor and
    authorized by Engineer as truly representing the configuration of the particular areas.

    10.1.7 Safety Requirements ta


    qa
    1 The Contractors attention is drawn to the hazards involved in working in confined spaces
    including sewers, sewer manholes, inspection chambers, wet wells, pumping stations and
    as

    ancillary structures. The Contractor shall be responsible for ensuring that adequate
    precautions are taken to ensure safe working conditions.
    se

    2 The Contractor shall give evidence of having carried out training in avoiding the following
    risks associated with working in confined spaces in sewerage pipelines:
    er

    (a) presence of toxic, flammable and explosive gases


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    (b) persons falling


    (c) falling objects
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    (d) drowning
    et

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

    (a) definition of confined spaces


    (b) atmospheric hazards
    (c) purpose and practical use of gas monitoring equipment
    (d) practical use and maintenance of safety equipment such as breathing apparatus,
    safety harnesses, life lines and lifting frames
    (e) personal protective equipment such as hard hats, gloves and safety boots
    (f) health hazards
    (g) hygiene procedures
    (h) basic first aid procedures
    (i) pre-entry procedure
    (j) entry procedure
    QCS 2014 Section 08: Drainage Works Page 5
    Part 10: Pipeline Cleaning and Inspection Survey

    (k) exit procedure


    (l) rescue procedure.

    All training courses shall involve both class room instruction and hands-on practical training
    which should include both entry and rescue drills.

    4 Safety and Protective Equipment. The Contractor shall safeguard his work force against
    physical injury caused by falling or being struck by falling objects. Precautions shall include,
    but are not limited to, the provision of the following equipment for each person working in
    confined spaces:

    (a) safety helmet with chin guard


    (b) safety boots
    (c) safety harness

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    (d) PVC gloves/gauntlets

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    (e) overalls

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    (f) rubber boots
    (g) ear, eye, and face protection, where applicable.

    5 ta
    In addition to the above, each gang working in a confined space shall have with them:
    qa
    (a) four sets of 15 m life lines with spring shackle one end, eye at other
    (b) portable ladder
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    (c) lifting frame complete with ropes and shackles for hand operation
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    (d) powerful hand lamp, explosion proof (intrinsically safe)


    (e) ventilation blower together with portable generator and flexible ducting
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    (f) position pressure respiration face masks with associated portable compressor or air
    line system supplying air via compressed cylinders
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    (g) gas detectors capable of detecting both high and low oxygen, hydrogen sulphide and
    methane gas explosion proof (intrinsically safe).
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    6 All safety and protection equipment shall be regularly maintained and inspected by a
    competent person. Gas monitors shall be calibrated in accordance with the manufacturers
    et

    recommendations and a certificate issued with the date of calibration.


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    7 Each group of workers engaged in working in sewers, manholes, pumping stations and
    ancillary structures shall be provided with, and shall be familiar with the operation of gas
    testing equipment suitable for checking hydrogen sulphide, combustible gases, and lack of
    oxygen. Before entering confined spaces the atmosphere within such spaces shall be tested
    and certified as safe for entry by the responsible person to ensure that there is no build up of
    hydrogen sulphide or combustible gases, nor lack of oxygen. When working in sewers where
    accumulation of sludge or silt exists, the Contractor's attention is drawn to the fact that, when
    disturbed, sludge may release toxic gases. Adequate ventilation facilities shall be provided
    and continuous monitoring shall be made while work is in progress in live sewers or
    structures containing sludge or silt.

    8 Should anyone working in a confined space complain of nausea or dizziness, all personnel
    shall be removed from that location immediately. Work may resume only when it is certified
    safe to do so, using breathing apparatus if necessary.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 10: Pipeline Cleaning and Inspection Survey

    9 The Contractor shall safeguard his work force against health hazards while working in sewers
    and inform his work force of the dangers of bacterial infection while working in a sewage
    contaminated environment, and shall impress upon them the importance of personal
    hygiene. All members of the work force shall be fit, and everyone who will be expected to
    work in sewers shall not suffer from:

    (a) Any heart defect.


    (b) Any history of fits or blackouts.
    (c) Deafness or loss of balance.
    (d) Claustrophobia.
    (e) Recurrent back ailments.
    (f) Shortage of breath on light exertion.

    .
    10 All members of the work force shall be vaccinated against tetanus, typhoid, paratyphoid,

    l
    .l.
    hepatitis A and B and cholera, and shall each carry an up-to-date medical record on their
    person. The Contractor shall provide a medical certificate of fitness for all his personnel.

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    11 The Contractor shall keep personal hygiene and emergency equipment within easy access of
    each working group. Emergency equipment which shall include but not be limited to:

    (a) Barrier cream. ta


    qa
    (b) Disinfectant.
    (c) First-aid kit with eye bath.
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    (d) Stretcher.
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    (e) Life lines 15 m long with spring shackle one end, eye at other.
    (f) Lifting harnesses.
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    (g) Two sets of breathing apparatus with air bottle.


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    12 The address and telephone number of the nearest hospital with emergency facilities shall be
    posted in each working location.
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    13 The Contractor shall be solely responsible for liability for any claim or legal action arising as a
    it

    result of an accident and shall not be absolved of any liability under the Contract for his
    et

    having conformed to the above requirements.


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

    10.2 SEWER CLEANING

    10.2.1 Scope

    1 The cleaning of sewer pipelines and appurtenances includes but is not limited to the following
    elements:

    (a) location of manholes and chambers using suitable detection techniques and removal
    of overburden where necessary
    (b) cleaning of manholes and chambers with either or both water jetting or wire brushing
    or other means approved by the Engineer
    (c) removal of any grit and debris from manhole bases and benching
    QCS 2014 Section 08: Drainage Works Page 7
    Part 10: Pipeline Cleaning and Inspection Survey

    (d) providing cutoff walls and overpumping where necessary


    (e) water jetting including vacuum suction of debris
    (f) bucket and winch dredging, balling, kiting, pipeline internal gauging, or any other
    cleaning process as approved by the Engineer
    (g) flushing with water
    (h) removal of all sand, grit and debris jetted or dredged from the sewers and disposal of
    same to a disposal site required by the Engineer
    (i) controlling of odour and nuisance arising out of rehabilitation works, flow diversion or
    overpumping.

    10.2.2 Cleaning of Sewer Pipelines

    1 Cleaning of sewers and manholes before inspection surveys shall include one or more of the

    .
    above operations. The Contractor should note that pipelines, manholes, may have structural

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    defects cracks etc., and may have been completely filled with sand, grit, sediment and other
    debris and the requirement to accurately measure the vertical inside diameter of the sewer

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    necessitates that the invert of the sewer to be free of all sediment. The Contractor shall allow
    for the removal of all such material and disposal of same to a disposal site approved by the
    Engineer. Cleaning of sewers shall progress downstream.

    2 ta
    Sewer cleaning shall be thorough and shall only be carried out by methods approved by the
    qa
    Engineer to remove all deposits, foreign matter, solid or semi-solid and hard intruding
    material and all other debris including sand, silt, slime, sludge, sediment, grease, roots, loose
    flaky or soft pipe wall materials, loose concrete from walls and underside of cover slabs and
    as

    benching of manholes from within sewers and manholes. The liquid biological element of the
    sludge may be returned to the sewer system after suitable filtering methods to be agreed with
    se

    the Engineer.
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    3 Where cast iron junction pieces have been used, the Contractor shall ream out or grind off
    the corrosion products to produce a pipe of diameter equal to the adjacent pipes. Care shall
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    be taken to grind off all burrs which may otherwise puncture in-situ lining tubes during
    subsequent renovation works.
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    4 Pump station wells shall be cleaned where necessary to permit pipeline cleaning.
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    5 The designated sewer/manhole sections shall be cleaned using hydraulically propelled, high-
    et

    velocity jet, or mechanically powered equipment. The equipment and methods selected shall
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    be satisfactory to the Engineer. The equipment shall be capable of removing dirt, grease,
    rocks, sand, and other materials and obstructions from the sewer lines and manholes. If
    cleaning of an entire section cannot be successfully performed from one manhole, the
    equipment shall be set up on the other manhole and cleaning again attempted. If, again,
    successful cleaning cannot be performed or the equipment fails to traverse the entire
    manhole section, it will be assumed that a major blockage exists and the cleaning effort shall
    be temporarily abandoned until further notification by the Engineer.

    6 If the Contractors cleaning equipment becomes lodged in a sewer it shall be removed by the
    Contractor at his own expense. This shall include excavation, repair of sewer, backfill and
    surface restoration.

    7 All sludge, dirt, sand, rocks, grease, and other solid or semi-solid material resulting from the
    cleaning operation shall be removed at the downstream manhole of the section being
    cleaned. Passing material from manhole section to manhole section, which could cause line
    stoppages, accumulations of sand in wet wells, or damage pumping equipment, shall not be
    permitted.
    QCS 2014 Section 08: Drainage Works Page 8
    Part 10: Pipeline Cleaning and Inspection Survey

    8 Roots shall be removed in the designated sections where root intrusion is a problem. Special
    attention should be used during the cleaning operation to assure almost complete removal of
    roots from the joints. Procedures may include the use of mechanical equipment such as
    rodding machines, bucket machines and winches using root cutters and porcupines, and
    equipment such as high-velocity jet cleaners.

    9 All solids or semi-solids resulting from the cleaning operations shall be removed from the site
    and disposed of at an approved off-site disposal facility. All materials shall be removed from
    the site no less often than at the end of each workday. Under no circumstances will the
    Contractor be allowed to accumulate debris, etc., on the site of work beyond the stated time,
    except in totally enclosed containers and as approved by the Engineer.

    10 Acceptance of sewer line cleaning shall be made upon the successful completion of the
    television inspection and shall be to the satisfaction of the Engineer. If CCTV inspection
    shows the cleaning to be unsatisfactory, the Contractor shall be required to reclean and
    reinspect the sewer line until the cleaning is shown to be satisfactory.

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    10.2.3 Jetting

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    1 Jetting shall be carried out using motorised jetting vehicles specially designed for the work
    involved and complete with an integral water tank. Jetting shall be carried out at an
    appropriate water pressure such that no damage to pipes occurs. The jetting pump shall

    ta
    have the capability to vary the water pressure at the jetting nozzle and be equipped with a
    sufficient length of suitable armoured bore hose and jetting heads to accommodate all
    qa
    possible working conditions and pipe size in the sewer system. Jetting pressure to be
    approved by the Engineer.
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    2 Brackish water shall not be used for cleaning. Treated sewage effluent may be used subject
    to the approval of the Engineer.
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    3 The hose shall be mounted on a power operated drum reel having variable speed and
    direction controls and a meterage indicator. The hose shall be equipped with a variety of
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    nozzles totalling 15 to 30 including rear jets only, rear plus forward jets, rear plus side jets,
    and other such configurations necessary to ensure adequate cleaning of the pipeline.
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    Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.

    4 During all jetting operations the channel of the downstream sewer manhole shall be provided
    o

    with a cut off wall and all decumulated grit and debris shall be removed.
    it
    et

    5 Hydraulically propelled equipment shall be of a movable dam type and be constructed in such
    a way that a portion of the dam may be collapsed at any time during the cleaning operation to
    m

    protect against flooding of the sewer. The movable dam shall be the same diameter as the
    pipe being cleaned and shall provide a flexible scraper around the outer periphery to ensure
    removal of grease. Sewer cleaning balls or other equipment which cannot be collapsed shall
    not be used.

    6 Mechanically powered rodding machines shall be either a sectional or continuous rod type
    capable of holding a minimum of 200 m of rod. The rod shall be specifically heat-treated
    steel. To ensure safe operation, the machine shall be fully enclosed and have an automatic
    safety clutch or relief valve. Buckets, scrapers, scooters, porcupines, brushes and other
    mechanical equipment may also be utilised.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 10: Pipeline Cleaning and Inspection Survey

    7 All equipment and devices shall be operated by experienced personnel so that sewer lines
    are not damaged in the process of cleaning. When hydraulically propelled tools (which
    depend upon water pressure to provide their cleaning force), or tools which retard the flow in
    the sewer line are used, all necessary precautions shall be taken to ensure that the water
    pressure created does not damage or cause flooding of property being served by the sewer.
    When possible, the flow of sewage in the sewer shall be utilised to provide the necessary
    pressure for hydraulic cleaning devices. When additional water from water mains is
    necessary to avoid delay in normal work procedures, the water shall be conserved and not
    used unnecessarily.

    10.2.4 Winching

    1 The jetting machine shall incorporate a power-driven cable drum having not less than 200 m
    of 13 mm steel cable. The cable drum shall be mounted on an A-frame, fixed to the vehicle
    or trailer high enough off the ground to allow the bucket to be lifted above ground level. The
    backpull machine shall incorporate a power-driven cable drum with not less than 200 m of

    .
    nylon rope or light steel cable. The working machine shall have a swinging arm fixed to the

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    .l.
    top of the A-frame. The swinging arm shall be capable of lifting the bucket clear of the ground
    and rotating it away from the manhole for emptying. A chute with rollers and a shaker bar

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    may be used subject to the approval of the Engineer.

    10.2.5 Bucketing

    1 ta
    A range of bucket sizes shall be provided to suit the various pipe diameters. The buckets
    qa
    shall be cylindrical in cross-section with bails at each end having centre eye lugs and shall be
    of the clam shell type with the bottom made of two hinged halves such that when the bucket
    is pulled in the reverse direction, bottom first, the jaws open permitting debris to pass
    as

    through. When the bucket is pulled forward the jaws shall close, thereby retaining any
    material in the bucket or which subsequently enters. Both ends of the bucket shall be able to
    se

    dig into and scrape sediments and debris from the sewer invert.

    10.2.6 Balling or Kiting and Pipeline Internal Gauging


    er

    1 Balls shall be of inflatable rubber or other material approved by the Engineer having an
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    outside spiral thread and a swivel connection. With a hydraulic head differential of
    approximately 0.6 m, the ball shall rotate rapidly and produce a scouring jet on its periphery.
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    2 Suitable cable or rope shall be attached to the swivel connection fed from a cable drum
    it

    mounted on an A-frame complete with braking facilities. A manhole jack and cable guide
    et

    roller shall be used to feed the cable into the sewer. If the flow in the sewer is insufficient to
    produce adequate scouring velocity, the Contractor shall provide the additional supply of
    m

    water to overcome the deficiency.

    3 Kites may be used as an alternative to balls for sewers 600 mm diameter and above.

    4 Pipeline internal gauges shall not be used unless attached to lines in both upstream and
    downstream manholes.

    5 During all balling, kiting or gauging operations, the channel of the downstream manhole shall
    be provided with a cut off wall and accumulated debris removed.

    6 Sewer cleaning balls or other equipment which cannot be collapsed shall not be used.

    10.2.7 General Cleanliness of Areas during Sewer Cleaning

    1 The Contractor shall take all necessary precautions to ensure that during the sewer cleaning
    operations there is no spillage of sewage and debris onto the streets and other areas. When
    spillage occurs, the Contractor shall immediately remove all spillage and clean all surfaces to
    their original condition.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 10: Pipeline Cleaning and Inspection Survey

    10.3 SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING

    10.3.1 Scope of Work

    1 CCTV survey and sonar scanning shall be carried out only after satisfactory cleaning of the
    pipeline as specified in Clause 10.2 of this Part. The CCTV survey and sonar scanning shall
    include but not be limited to:

    (a) Production of colour video tape recording on compact disc (CD) and coding.
    (b) Accurate profiling of the cross-section of sewers and measurement of deflections.
    (c) Still colour pictures from a video graphic printer of the inside of sewers and manholes,
    inspection chambers and grease and oil interceptors, as directed by the Engineer.
    (d) Recording the complete survey on a computer database in accordance with WRC
    Manual of Sewer Condition Classification.

    .
    (e) Pictures to be printed in a digital format (Tiff) for computer data storage and retrieval.

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    .l.
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    10.3.2 Survey Requirements

    1 The rate of travel of the camera shall be such as to enable all details to be extracted from the
    video tape recording.
    ta
    qa
    2 The axis of the camera shall be arranged to coincide with the centreline of the pipe.

    3 The picture transmitted by the CCTV scanning camera (a scanning camera which can view
    as

    lateral connections to sewers) and sonar scanner shall be free from interference and loss of
    vertical and horizontal hold. The picture shall be in focus, properly illuminated, of good
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    contrast and without distortion. If vision is obscured at any time by the fouling of the lens, or
    lighting system, or if travel is impeded by obstructions, the camera shall be withdrawn and the
    defect rectified immediately.
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    4 The Contractor shall record the complete survey on a video tape format conforming with the
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    recording equipment manufacturers specification. The recording shall provide a continuous


    display of data on the monitor screen comprising the following information:
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    (a) automatic update of camera meterage


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    (b) date, day, month and year


    et

    (c) direction of survey - upstream or downstream


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    (d) gradient of sewer


    (e) nominal diameter of sewer and the actual measured horizontal, vertical and diagonal
    diameters at close intervals as directed by the Engineer
    (f) manhole/pipe type length reference number
    (g) sewer use
    (h) time of start of survey
    (i) location reference.

    5 The video recording shall be stopped whenever the camera is stationary for more than
    5 seconds and shall have manual override capability.

    6 The completeness of the video tapes shall be an accurate record of the sewer system which
    identifies and locates sewer defects, provides information that permits accurate analysis of
    the cause, extent, nature and severity of sewer deterioration and the measurement of
    horizontal, vertical and diagonal diameters of sewer and their locations.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 10: Pipeline Cleaning and Inspection Survey

    7 Portions of video tape marred by interference, or otherwise unacceptable shall be erased and
    the relevant portion of sewer shall be resurveyed and rerecorded. The Engineers decision as
    to the acceptability of any video recording shall be final.

    8 Still colour photographs as designated under Clause 10.3.5.

    9 The photographic negatives, the master video tapes, and a copy of the video tapes shall be
    handed over to the Engineer and shall become the property of the Employer.

    10 If a self-propelled camera is used, it shall incorporate features to enable it to be winch drawn


    without affecting the quality of the video recording.

    11 The location of any conditions that may result in a limitation of rehabilitation techniques that
    could be used and/or prevent proper installation of designated rehabilitation materials in the
    pipelines shall be noted. The Contractor shall propose corrective measures and/or alternative
    methods of rehabilitation for the approval of the Engineer.

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    10.3.3 Survey Equipment

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    1 The CCTV survey and sonar scanning equipment shall be modern and of advanced design
    and shall be tested and calibrated immediately before beginning work. The equipment shall
    be tested as designated herein by the manufacturers or an approved independent test

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    laboratory at intervals of not more than 6 months. Original certificates of compliance with the
    specifications of this Part shall be submitted to the Engineer before beginning work. The
    qa
    equipment shall include but not limited to the following:

    (a) CCTV camera and sonar scanner suitable for mounting on the same trolley as and
    as

    when required
    (b) colour TV camera with swivel, lift and radial device and able to focus on points of
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    interest
    (c) camera light head assembly with sufficient illumination for the diameter of sewer
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    pipes
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    (d) camera wheeled/tracked crawler assembly, self-propelled/flexible-shaft driven and


    remotely operated with forward, reverse, left, right stop and load indication
    (e) cable reel of minimum 200 m cable length with fully automatic and microprocessor
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    controlled cable handling facility


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    (f) power winch with either lockable or ratcheted drums


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    (g) CCTV/Sonar central control units


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    (h) colour TV monitor


    (i) high-resolution scanning device including high speed pipe profiler and software to
    interpret the signals
    (j) video cassette recording system with audio video information system
    (k) all standard and optional accessories recommended by the manufacturers.

    2 The picture quality of the camera shall be tested using the Marconi Resolution Chart No. 1 or
    equivalent clearly defined with no tinting to show white, yellow, cyan, green, magenta, red,
    blue and black.

    3 The quality of the CCTV electronics, camera and monitor shall be such that the following
    criteria are satisfied and if any of the criteria are not met during the survey the lengths of
    sewer so affected shall be resurveyed at the Contractors expense:

    (a) Shades of Grey. The grey scale shall show equal changes in brightness ranging from
    black to white with a minimum of five stages
    QCS 2014 Section 08: Drainage Works Page 12
    Part 10: Pipeline Cleaning and Inspection Survey

    (b) Colour. With the monitor control adjusted for correct saturation, the six colours plus
    black and white shall be resolved with the primary and complementary colours in
    order of decreasing luminance. The grey scale shall appear in contrasting shades of
    grey with no tint
    (c) Linearity. The background grid shall show squares of equal size, without
    convergence or divergence over the whole picture. The centre circle shall appear
    round and have the correct height/width ratio within 5 %
    (d) Resolution. The live picture shall be clearly visible with no interference and capable
    of registering a minimum number of TV lines/picture height lines. The resolution shall
    be checked with the monitor colour control turned down. For tube type cameras this
    shall be 350 lines and for CCD type cameras it shall be 250 lines
    (e) Colour Consistency. The colour on the live picture and that on the video picture shall
    be consistent with that described for the Marconi Resolution Chart No. 1.

    4 The camera shall be capable of taking clear pictures in any direction; i.e., 90 to the left and

    .
    90 to the right (total 180 in horizontal axis) and also 360 in the circumference of the pipe

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    without using extra revolving mirror attachment.

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    5 The camera shall continuously transmit distance at each meter length, electronically matched
    to the movement of the camera with a maximum tolerance of 0.1 % on the control TV
    monitor and the resultant video tapes.
    ta
    qa
    6 The camera shall indicate the degree of inclination of the sewer line with tolerance of 0.2 %
    on the TV monitor with a printout of the slope.

    7 The camera crawler assembly shall be adjustable for deployment in sewers of varying
    as

    diameters. When required, both sonar scanning and CCTV equipment shall be mounted on
    the same crawler assembly.
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    8 The video tape recording of the transmission for CCTV and Sonar scanning units shall be
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    provided to accurately record on video tapes, of quality approved by the Engineer. In the
    central control unit, the operator shall have remote facilities to control the camera, the cable
    ov

    drum and power winch.

    9 Each unit shall carry sufficient number of guides and rollers to ensure that, when surveying all
    o

    bonds are supported away from pipe and manhole structures and all CCTV cables and lines
    it

    used to measure the cameras location within the sewer are maintained in a taut manner and
    et

    set at right angles, where possible, to run through or over the measuring equipment.
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    10 At the start of each and every working shift, the camera shall be positioned centrally and at
    right angles to the test card at a distance where the full test card just fills the monitor screen,
    ensuring that the edges of the test card castellation coincide with the edges of the horizontal
    and vertical scan (raster). The card shall be illuminated evenly and uniformly without any
    reflection. The illumination shall be to the same colour temperature as the colour
    temperature of the lighting that will be used on the CCTV survey equipment in the pipe. The
    test shall be recorded for subsequent use by the Engineer, the recording time to be at least
    30 seconds. The type of camera used is to be identified on the test recording. The recording
    must show the camera being introduced into the test device and reaching its stop position.
    Other test devices may be used subject to approval by the Engineer.

    11 The Contractor shall note that the Engineer may periodically check both the live and recorded
    picture colour consistency against the colour bar. Any differences will necessitate re-survey
    of the lengths affected at the Contractors expense.
    QCS 2014 Section 08: Drainage Works Page 13
    Part 10: Pipeline Cleaning and Inspection Survey

    12 The adjustment of focus and iris shall allow optimum picture quality to be achieved and shall
    be remotely operated. The adjustment of focus and iris shall provide a minimum focal range
    from 50mm in front of the cameras lens to infinity. The distance along the pipe in focus from
    the initial point of observation shall be a minimum of twice the vertical height of the pipe. The
    illumination must be such as to allow an even distribution of the light around the pipe
    perimeter without the loss of contrast, flare out of picture or shadowing.

    13 Where the CCTV survey equipment is towed by winch and bond through the pipe, all winches
    shall be stable with either lockable or ratcheted drums. All bonds shall be steel or of an
    equally non-elastic material to ensure the smooth and steady progress of the CCTV survey
    equipment. All winches shall be inherently stable under loaded conditions.

    10.3.4 Survey Vehicle

    1 The CCTV and sonar scanning vehicles shall be equipped with the following three separate
    compartments:

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    (a) drivers cabin

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    (b) operator and viewers compartment (seating for minimum three persons)

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    (c) Camera and sonar scanner equipment storage compartment.

    2 The operator and viewers compartment shall be insulated against noise and extremes in
    ta
    temperature and be provided with means of controlling external and internal sources of light
    qa
    in a manner capable of ensuring that the monitor screen display complies with the specified
    requirements.
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    3 The equipment storage compartment shall have adequate space for equipment, both
    operational and stored. Equipment used in sewers shall not be stored in compartment.
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    4 The vehicle shall be equipped with air-conditioner for the drivers cabin and the operators
    room. A wireless communication system between the operator inside the vehicle and the
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    helper outside the vehicle shall be provided.


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    5 The vehicle shall be complete with all equipment and apparatus necessary to carry out a
    complete sewer inspection survey. Colour monitors, a sonar processor unit, replay and on-
    board reporting, video recorders, video printers, computers and computer printers to
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    generate survey reports and data base shall be provided. The operator/viewers compartment
    it

    shall be designed for optimum productivity.


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    6 The vehicle shall be equipped with the following road safety equipment:
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    (a) a minimum of two amber regulation flashing beacons fixed at diagonal corners of the
    vehicle, which shall operate continuously while the vehicle is stationary on the
    highway in a working situation
    (b) traffic signs and cones, which shall be displayed in accordance with the
    recommendations of the Traffic Police Section, with a minimum of:
    (i) four reflective boards: Arrow
    (ii) two reflective boards: Men Working (in English and Arabic)
    (iii) two reflective boards: Road Narrows (in English and Arabic)
    (iv) 20 reflective cones
    (v) 12 battery operated flashing road lamps.
    (c) a sufficient number of bright coloured overalls with fluorescent over-jackets or belts,
    which shall be worn by all operatives while working on roads.

    7 Relevant safety equipment specified in Clause 10.1.7 shall be made available.


    QCS 2014 Section 08: Drainage Works Page 14
    Part 10: Pipeline Cleaning and Inspection Survey

    10.3.5 Photographs

    1 After sewer cleaning and in parallel with the CCTV inspection, excellent quality still colour
    photographs 90 mm x 130 mm with the date and submitted in TIFF format an album with
    captions providing a detailed description, the precise location and reference numbers as
    designated shall be taken of:

    (a) the inside the sewer to show the typical conditions for each length of sewer. A
    minimum of three photographs per manhole length shall be taken at every junction
    piece, faulty joint, broken pipe, and other points of interest as directed by the
    Engineer
    (b) the interior of each manhole, chamber and grease/oil trap. A minimum of three
    photographs shall be taken of each structure showing the general extent of corrosion
    to the structures walls, bases, benching and the underside of cover slabs as directed
    by the Engineer

    .
    2 Photographs shall be taken of the internal condition of the pipes at the beginning of a defect,

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    at service connections and such other places as the Engineer shall direct. Where defects
    exist at adjacent points, photographs should not be taken at intervals of less than 2m unless

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    absolutely necessary to show the second defect. Where photographs are not otherwise
    required, a general condition photograph shall be taken at every l0m.

    3
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    Photographs must clearly and accurately show what is displayed on the monitor which shall
    be in proper adjustment.
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    4 Photographs shall be clearly identified in relation to the location (minimum requirement
    manhole start and finish numbers or pipe length reference numbers) survey direction,
    as

    chainage, photograph number, and date when the photograph was taken. The annotation
    shall be clearly visible and in contrast to its background, shall have a figure size no greater
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    than 5mm, and be type printed. The annotation shall be so positioned as not to interfere with
    the subject of the photograph.
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    5 Hard copy of the photographs shall be supplied in suitable A4 sized plastic holders and
    bound in ring binders or lever arch files. The photographs shall be presented in chronological
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    order and each file shall contain a contents page providing clear cross-referencing to the
    report. The minimum requirements of the contents page shall be locations (district, street
    name and road number), photograph numbers and dates when photographs were taken.
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    10.3.6 Site Coding Sheets


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    1 Site coding sheets detailing the condition of each pipe length and manhole shall be
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    completed in the format of the WRC Manual of Sewer Condition Classification and as
    approved by the Engineer. These sheets shall be submitted to the Engineer with the video
    tape to which they refer. A draft copy of the coding sheets shall be submitted weekly to the
    Engineer for his approval. When requested by the Engineer, more frequent reports of
    selected parameters shall be submitted.

    2 The site coding sheets shall be standardised to the approval of the Engineer to indicate the
    following minimum requirements:

    (a) location reference to sewer length concerned


    (b) nominal diameter of sewer
    (c) actual measured horizontal, vertical and diagonal diameters of sewer and their
    locations, as a continuous computer printout at close intervals and as directed by the
    Engineer
    (d) date of survey
    (e) direction of survey
    QCS 2014 Section 08: Drainage Works Page 15
    Part 10: Pipeline Cleaning and Inspection Survey

    (f) time of start of survey


    (g) sewer gradient
    (h) trial hole records
    (i) coded reference to any defects encountered
    (j) location of defects
    (k) location of any junctions or laterals encountered
    (l) location of any still photographs taken.

    3 In addition to the final report and any interim reports on a section of the pipe as defined
    above, the Contractor shall provide the Engineer with the following:

    (a) One copy of the completed survey report coding forms at the end of each working
    shift.

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    (b) One copy of sheets containing the pipe reference number, distance, orientation and
    deflection measurements of the pipes surveyed at the end of each working shift.

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    (c) One copy of photographs and recordings on a weekly basis as the work progresses or
    as previously agreed with the Engineer in writing.

    10.3.7 Excavation
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    1 When directed by the Engineer, the Contractor shall excavate and expose sections of sewer
    for examination.
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    2 The Contractor shall carry out such excavations expeditiously and shall break or expose the
    sewer section upon removal from the trench for detailed physical examination and testing.
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    3 Excavations shall be carried out in accordance with Part 2 of this Section.


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


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

    (a) site coding sheets


    (b) correctly labelled video tapes of approximately one hour duration
    (c) pictures on compact discs in a digital format (Tiff)

    2 The report shall be completed using a computer based database with software that shall be
    fully compatible with the Oracle database used by the Ministry of Municipal Affairs &
    Agricultures ARC INFO GIS system and approved by the Engineer. One copy on a 3.5 inch
    diskettes of all computer generated data shall be provided with the report. Four copies of
    draft report shall be submitted for Engineers approval followed by final report incorporating
    appropriate responses to the Engineers comments.
    QCS 2014 Section 08: Drainage Works Page 16
    Part 10: Pipeline Cleaning and Inspection Survey

    3 The Contractor shall enter the information obtained from the survey into a computer
    database in accordance with the WRC manual of sewer classification which shall allow for
    the storage, retrieval and analysis of this information. Furthermore the database shall link the
    survey information with an electronic drawing of the pipeline which shall allow the viewing of
    still images representative of the major problems identified by the survey.

    4 The Contractor shall supply 2 copies of each recording in CD format.

    5 The condition survey report shall include the following:

    (a) Pipe condition classification in accordance with the WRC format.


    (b) Manhole/pipe length reference numbers.
    (c) Date of survey.
    (d) Road name/location.
    (e) Direction of survey.

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    (f) Time of start of survey.

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    (g) Weather conditions.
    (h) Pipe dimensions.
    (i)
    (j)
    Materials of construction.
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    (k) Profiling of pipe cross sections to give a complete circumferential profile and
    deflections within the pipe.
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    (l) Clock position of all connections including meterage from manhole.


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    (m) Whether or not connections are dry and running.


    (n) Location and description of obstructions, structural defects, missing pieces of pipe,
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    open and/or offset joints, ovality, leakage or evidence thereof, corrosion, erosion,
    break-in connections, protruding connections, mineral deposits, roots, previous
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    repairs, sags and other abnormalities with respect to the pipelines condition with
    counter distance in metres from the start manholes centreline.
    (o) Photographs as specified herein.
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    (p) Recommendations, including options and alternative methods to extend the service life
    by a further 50 years by lining, replacement or other refurbishment.
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    (q) Estimated cost and programme for carrying out the recommendations.
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    6 If the Engineer requires separate survey reports for any section of the survey or requires
    some or all of the section to be grouped together in a single survey report he shall notify the
    Contractor accordingly.

    10.4 OVERPUMPING AND FLOW DIVERSION

    10.4.1 Source of Flow

    1 Manholes and sewers being worked on shall be completely isolated and by-passed such that
    they do not contain any sewage. This shall be achieved by plugging, pumping and bypassing
    or diverting the flow.

    2 When flow in a sewer line is plugged, pumped and bypassed or diverted sufficient
    precautions must be taken to protect the sewer lines from damage that might result from
    sewer surcharging. Further, precautions must be taken to ensure that sewer flow control
    operations do not cause flooding or damage to public or private property being served by the
    sewers involved.
    QCS 2014 Section 08: Drainage Works Page 17
    Part 10: Pipeline Cleaning and Inspection Survey

    3 The Contractor shall submit his proposed method of overpumping or flow diversion to the
    Engineer for approval.

    4 The Contractor shall co-ordinate and agree all his activities on live facilities with the Drainage
    Affairs Maintenance Department staff responsible for upkeep of the drainage system. A
    signed Permit to Work shall be obtained from Maintenance Department prior to the
    commencing the work.

    10.4.2 Pipe Stoppers

    1 The flow shall be stopped off using pipe stoppers of a type approved by the Engineer. The
    stopper shall be of circumferential compressible rubber rings fully inserted inside the pipe
    before tightening. Inflatable type stoppers for sewers less than 300 mm diameter shall be of
    a type approved by the Engineer.

    2 Stoppers shall be suitable for the sizes and classes of pipe in which they are used and must

    .
    not cause damage to existing pipes. Stoppers must be able to withstand the maximum

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    possible differential head at each location and shall be fully restrained in accordance with the
    manufacturers recommendations.

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    3 The Contractor shall be solely responsible for maintaining such stoppers in good working
    condition and for the consequences of any failure thereof.

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    Where a section of the sewerage system is isolated for work involving man-entry to the
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    isolated area, a minimum of two stoppers shall be used at each boundary location isolating
    the area from the main sewer and subsidiary sewers. At least one of these stoppers at each
    location should be of an approved pneumatic type.
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    10.4.3 Stopping Off Flow


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    1 For the length of sewer being surveyed, the Contractor shall plug off the outlet of the
    downstream manhole and the inlet to the upstream manhole. The next upstream manhole
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    shall be used as a pumping sump with the outlet to that manhole also being plugged off.
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    2 All service connections discharging into the plugged off sewer shall be satisfactorily isolated
    the overpumping system shall be provided to the approval of the Engineer.
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    1 Interruption of service will not be permitted.


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    10.4.4 Pumping Plant


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    1 Overpumping shall be carried out using suitable mobile pump sets of adequate capacity and
    head to the approval of the Engineer.

    2 The Contractor shall provide sufficient number of standby pumps of adequate capacity.
    Where required by the Engineer, a temporary sump shall be provided to prevent surcharging
    of upstream sewers.

    3 The pumps shall be controlled by suitable level controls installed to operate at levels to be
    approved by the Engineer and shall be capable of dealing with the flow in the sewer and any
    material likely to be transported in it without being blocked.

    10.4.5 Sewage Flooding

    1 Full-time attendance with mobile phone facilities shall be provided by the Contractor at each
    pumping location such that in the event of mechanical breakdown, flooding or blockage,
    immediate assistance will be summoned.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 10: Pipeline Cleaning and Inspection Survey

    10.4.6 Overpumping of Flow

    1 Pumped sewage flows shall be discharged to a manhole downstream of the sewer length
    being cleaned or surveyed. The open end of the pump delivery pipe shall be laid in order to
    minimise turbulence of the pumped flow. No sewage shall be dumped onto any surfaces
    outside the sewer system.

    2 The pump delivery pipe shall be of suitable armoured material which in all locations subject to
    traffic flow shall be suitably protected with preformed steel plates bridging the pipe or by other
    means approved by the Engineer. Such protection shall be adequate to allow passage of
    vehicular traffic over the pipe.

    10.4.7 Temporary Diversion of Flow

    1 Where temporary sewer diversion is required the Contractor shall notify the Engineer
    accordingly and submit his proposals for implementation of such diversion.

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    2 The Contractor shall obtain all other permissions and approvals from relevant authorities
    prior to commencement of such diversion. On completion of temporary diversionary works

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    the temporary pipelines shall be removed or be adequately sealed and inlet and outlet
    manholes reinstated to their original condition.

    10.4.8 Entrances to Private Properties


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    1 The Contractor shall not cause any obstruction to the access of private properties. If the
    obstructions are unavoidable, the Contractor shall provide and maintain in good order
    alternative access to the approval of the Engineer.
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    10.4.9 Odour and Noise Control During Flow Diversion and Overpumping
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    1 The Contractor shall take necessary precautions for controlling odour and noise with
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    prescribed limits approved by the Engineer and for preventing nuisance and inconvenience to
    the local residents and the public during the flow diversion and overpumping operations.
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    2 The Contractor shall include in his method statement, the measures to be taken for noise
    and odour control.
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    3 The Contractor shall provide special measures to prevent the odour release to the approval
    of the Engineer.
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    4 The Contractor shall install temporary chemical dosing system to contain the odour release if
    other measures fail.

    5 For odour control, the measurement of hydrogen sulphide shall not be more than 1 ppm
    measured at a distance of 1m from the point of discharge to the adjacent property.

    10.5 CONTRACTORS QUALITY CONTROL PROCEDURE


    1 The Contractor shall operate a quality control system, to be approved by the Engineer, which
    will effectively gauge the accuracy and consistency of the CCTV survey report produced by
    the operator from the monitor picture.

    2 The system shall be such that the accuracy of reporting should be a function particularly of:

    (a) The number of faults not recorded (omissions).


    (b) The correctness of the coding and classification of each fault recorded.

    3 The minimum levels of accuracy to be attained shall be as follows:


    QCS 2014 Section 08: Drainage Works Page 19
    Part 10: Pipeline Cleaning and Inspection Survey

    (a) Header accuracy 95%


    (b) Detail accuracy 85%
    (c) Lowest acceptable tolerance 75%

    4 The Engineer shall be entitled in accordance with Section 1 Part 8 and this section to audit
    periodically the control system and be present when assessments are being computed.

    5 When requested by the Engineer, the Contractor shall forward to the Engineer sufficient
    details and information for this audit assessment.

    6 Should any report fail to achieve the specified percentages for a particular pipe length, the
    Engineer shall require the Contractor to re-code and re-submit the report. If the accuracy
    check fails, the Contractor shall repeat the full quality control check on 10 surveys, 5 surveys
    either side of the survey which has failed. If any further failures are found to be outside the
    tolerances laid down above within these additional checks, the process will be repeated until
    an acceptable standard is reached. Any reports that have failed will be re-coded by another

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    qualified surveyor and submitted to the Engineer to replace those in his possession.

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    7 Quality selection is achieved by using two parameters:

    (a) Population - the anticipated number of surveys carried out by one surveyor over a
    period of time (normally I year).
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    Sample size - the number of surveys required to be checked to satisfy the quality
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    control validity.

    8 The sample surveys for quality control are to be selected by the use of computer generated
    as

    random numbers (ERNI) or other such equivalent method and shall be 5% of the total
    population. Each surveyor shall have a different set of random numbers, which are sorted
    into chronological order, and are renewed once the population size has been reached. The
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    random numbers shall not be disclosed to the surveyor until they have been used up.
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    9 On site the surveyor logs certain information on the surveys being carried out and in the order
    in which they are surveyed.
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    10 The in-office staff then count, through the surveys that have taken place and copy those
    reports that coincide with the random numbers.
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    11 Copy of the relevant section of the recording shall also be made available.
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    12 Information on the recording and its contents are entered on a survey selection log.
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    13 Header information - All header information shall be checked to ensure that left and right
    justified entries are correctly entered, alpha or numeric symbols are correctly used and all
    compulsory boxes filled in. The percentage of accurate entries shall be ascertained and any
    that fall below the value specified shall be rejected. All decimal percentage points shall be
    rounded down to the nearest whole number.

    14 Detail information - Each error/omission is treated on an equal basis whether or not it is a


    minor or major error or omission. During the checking each error/omission is highlighted on
    the report from which the following totals are calculated for each survey report:

    (a) The number of actual entries that should have been made.
    (b) The number of actual errors/omissions made.

    15 These totals are entered on the right of the survey report being checked. Individual column
    totals are also calculated and entered on to the survey accuracy log.
    QCS 2014 Section 08: Drainage Works Page 20
    Part 10: Pipeline Cleaning and Inspection Survey

    16 The accuracy of each survey is arrived at by taking the number of actual errors/omissions
    away from the number of actual entries that should have been made and dividing the result
    by the number of actual entries that should have been made and multiplying by 100 to create
    a percentage.

    17 This percentage is entered on the survey detail rating form.

    18 The ongoing accuracy of the surveyor (the confidence level) is calculated by taking the
    mean of 5 percentage results (each 5 representing one control unit).

    19 Both the individual survey percentages and the mean results are entered onto the surveyors
    accuracy graph which has two boundaries:

    (a) Specified mean - the level of accuracy expected.


    (b) Specified tolerance - the level to which the accuracy can fall before specific action is
    taken.

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    20 Any surveyor whose quality control results fall below the specified mean on more than 2
    occasions or the specified tolerance at any time shall be deemed to have failed his quality

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    control criteria and shall be invalidated from acting as a team leader on this Contract until he
    has attended and passed an approved course for pipe condition classification.

    END OF PART
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    QCS 2014 Section 08: Drainage Works Page 1
    Part 11: Sewer Rehabilitation

    11 SEWER REHABILITATION ........................................................................... 3

    11.1 GENERAL ...................................................................................................... 3


    11.1.1 Scope 3
    11.1.2 References 3
    11.1.3 Definitions 5
    11.1.4 Submittals 6
    11.1.5 Quality Assurance 8
    11.1.6 Warranty 9
    11.2 GENERAL REQUIREMENTS ........................................................................ 9
    11.2.1 Work Programme Review, Cleaning, Inspection 9

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    11.2.2 Safety 9

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    11.2.3 Preparation for Installation of Linings 9

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    11.2.4 Delivery, Storage and Handling 11
    11.2.5 Annulus Grout 11
    11.3 ta
    SEALING OF PIPES AND MANHOLES ...................................................... 11
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    11.3.1 Scope 11
    11.3.2 Sealing Compounds 11
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    11.3.3 Joint Sealing of Pipes 12


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    11.3.4 Sealing of Manholes 14


    11.4 SLIPLINING OF SEWERS .......................................................................... 15
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    11.4.1 General 15
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    11.4.2 Materials 15
    11.4.3 Installation of Sliplining 16
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    11.5 DEFORMED PIPE LINER INSTALLATION ................................................. 18


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    11.5.1 Scope 18
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    11.5.2 Materials 18
    11.5.3 Installation 19
    11.6 CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD) ......... 20
    11.6.1 Scope 20
    11.6.2 Materials 21
    11.6.3 Installation of Cured-In-Place Liner 22
    11.7 SPIRAL WOUND PROFILE LINER ............................................................. 23
    11.7.1 Scope 23
    11.7.2 Materials 23
    11.7.3 Installation of Spiral Wound Profile Liner 25
    QCS 2014 Section 08: Drainage Works Page 2
    Part 11: Sewer Rehabilitation

    11.8 PIPE CRACKING OR BURSTING ............................................................... 26


    11.8.1 Scope 26
    11.8.2 General 26
    11.8.3 Materials 26
    11.8.4 Installation Equipment 27
    11.8.5 Installation 27
    11.9 INSPECTION AND TESTING OF PIPE LINES AFTER
    REHABILITATION ....................................................................................... 29

    11.10 MANHOLE REHABILITATION..................................................................... 30


    11.10.1 Scope 30

    .
    11.10.2 General 30

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    11.10.3 Materials 30

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    11.10.4 Rehabilitation of Manhole Walls and Bases 31
    11.10.5 Rehabilitation of Manhole Shafts and Slabs 31
    11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or
    Replacement ta 31
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    11.10.7 Inspection and Testing 32
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    11.11 MANHOLE LINING ...................................................................................... 32


    11.11.1 Scope 32
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    11.11.2 Materials 32
    11.11.3 Installation of Lining
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    32
    11.11.4 Inspection and Testing 33
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    QCS 2014 Section 08: Drainage Works Page 3
    Part 11: Sewer Rehabilitation

    11 SEWER REHABILITATION

    11.1 GENERAL

    11.1.1 Scope

    1 This Part includes the specifications for all work necessary to rehabilitate sewers, manholes
    and chambers including, but not limited to:

    (a) sealing of sewers and manholes


    (b) manhole rehabilitation
    (c) manhole lining

    .
    (d) sliplining of sewers

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    (e) deformed pipe lining

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    (f) cured-in-place pipe (inversion method)
    (g) spiral wound profile liner
    (h) pipe cracking or bursting.
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    2 Related Sections and Parts are as follows:
    This Section
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    Part 1 General
    Part 2 Earthworks
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    Part 4 Pipeline Installation


    Part 6 Metal Works
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    Part 7 Miscellaneous GRP Works


    Part 8 Painting and Protective Coatings
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    Part 10 Sewer Cleaning and Inspection Survey


    11.1.2 References
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    1 The following standards and other documents are referred to in this Part:
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    ASTM C923 M ............Specification for Resilient Connectors Between Reinforced Concrete


    Manhole Structures Pipes and Laterals [Metric]
    ASTM D543 ................Resistance of Plastics to Chemical Reagents
    ASTM D618 ................Methods of Conditioning Plastics and Electrical Insulating Materials
    ASTM D638 ................Standard test method for tensile properties of plastics.
    ASTM D746 ................Standard test method for brittleness temperature of plastics and
    elastomers by impact.
    ASTM D790 ................Standard Test Methods for Flexural Properties of Unreinforced and
    Reinforced Plastics and Electrical Insulating Materials
    ASTM D883 ................Definition of Terms Relating to Plastics
    ASTM D991 ................Standard test method for rubber property-volume resistivity of
    electrically conductive and antistatic products.
    ASTM D1238 ..............Standard test method for melt flow rates of thermoplastics by extrusion
    plastometer.
    QCS 2014 Section 08: Drainage Works Page 4
    Part 11: Sewer Rehabilitation

    ASTM D1248 ..............Specification for Polyethylene Plastics Moulding and Extrusion


    Materials
    ASTM D1505 .............Standard test method for density of plastics by the density gradient
    technique.
    ASTM D1525 ..............Standard test method for Vicat softening temperature of plastics.
    ASTM D1600 ..............Abbreviations of Terms Relating to Plastic Pipes
    ASTM D1693 ..............Test for Environmental Stress-Cracking of Ethylene Plastics
    ASTM D1784 ..............Specification for Rigid PVC Compounds and Chlorinated PVC (CPVC)
    Compounds
    ASTM D2122 ..............Method for Determining Dimensions of Thermosetting Pipe and
    Fittings by Acetone Immersion
    ASTM D2152 ..............Test Method for Degree of Fusion of Extruded PVC Pipe and Moulded
    Fittings by Acetone Immersion

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    ASTM D2240 ..............Standard test method for rubber property-Durometer hardness.

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    ASTM D2412 ..............Test Method for Determination of External Loading Characteristics of
    Plastic Pipe by Parallel-Plate Loading

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    ASTM D2444 ..............Test Method for Impact Resistance of Thermoplastic Pipe and Fittings
    by means of a Tup (Falling Weight)
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    ASTM D2657 ..............Practice for Heat-Joining Polyolefin Pipe and Fittings
    ASTM D2837 ..............Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials
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    ASTM D3035 ..............Specification for Polyethylene (PE) Plastics Pipe (SDR-PR) Based on
    Controlled Outside Diameter
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    ASTM D3350 ..............Specification for Polyethylene Plastics Pipe and Fittings Materials
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    ASTM D3753 ..............Specification for Glass-Fiber-Reinforced Polyester Manholes


    ASTM D4703 ..............Standard practice for compression moulding thermoplastic materials
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    into test specimens, plaques or sheets.


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    ASTM F412 ................Definitions of Terms Relating to Plastic Piping Systems


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    ASTM F477 ................Specification for Elastomeric Seals for Joining Plastic Pipe
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    ASTM F585 ................Practice for Insertion of Flexible Polyethylene Pipe into Existing
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    Sewers
    ASTM F714 ................Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on
    Outside Diameter
    ASTM F1216 ..............Rehabilitation of Existing Pipelines and Conduits by the Inversion and
    Curing of a Resin-Impregnated Tube
    ASTM F1248 ..............Standard test method for determination of environmental stress crack
    resistance (ESCR)of polyethylene pipe.
    ASTM F1533 ..............Standard specification for polyethylene (PE) pipe
    ASTM F1606 ..............Standard practice for rehabilitation of existing sewers and conduits
    with deformed polyethylene (PE) liner.
    ASTM F1697 ..............Standard specification for poly (vinyl chloride) (PVC) profile strip for
    machine spiral-wound liner pipe rehabilitation of existing sewers and
    conduits
    QCS 2014 Section 08: Drainage Works Page 5
    Part 11: Sewer Rehabilitation

    ASTM F1698 ..............Installation of Poly (Vinyl Chloride) (PVC) Profile Strip Liner and
    Cementitious Grout of Rehabilitation of Existing Man-Entry Sewers
    and Conduits
    ASTM F1741 ..............Standard practice for installation of machine spiral wound poly (vinyl
    chloride) (PVC) liner pipe for rehabilitation of existing sewers and
    conduits.
    ASTM F794 ................PVC Large Diameter Ribbed Gravity Sewer Pipe and Fittings based on
    Controlled Inside Diameter
    BS 2494......................Materials for elastomeric seals for joints in pipework and pipelines
    BS 4346......................Joints and fittings with unplasticized PVC pressure pipes
    BS 5556......................Specifications for general requirements for dimensions and pressure
    ratings for pipes of thermoplastic materials
    BS 5955......................Code of practice for plastic pipe work

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    BS 8010......................Pipelines

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    BS EN 752..................Sewerage
    BS EN 1401................Plastic piping systems

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    BS EN 13244..............Polyethylene pipes (type 50) in metric diameter for general purposes
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    BS EN 1852-1 ............Plastic piping system for non-pressure underground drainage and
    sewerage polypropylene (PP)
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    CP 312, ......................Plastic pipe work


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


    ISO 9000 ....................Quality Systems
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    ISO 9967 ....................Method for Determination of Long Term Ring Stiffness


    WRc ...........................Sewer Rehabilitation Manual
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    et

    11.1.3 Definitions
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    1 The following terms have the meanings hereby assigned to them except where the Contract
    clearly renders these meanings inapplicable:

    (a) Sliplining: insertion of a new liner pipe into an existing pipeline of larger diameter
    followed by grouting of the annulus.
    (b) Cured-in-place, inversion, in-situ or soft lining: the creation of a new pipe within an
    existing pipeline by insertion of a resin impregrated polyester felt liner by inversion
    under pressure lining inversion under pressure, the liner then being cured in-situ.
    (c) Spiral wound profile lining: insertion of helically wound, profile walled thermoplastic
    sections to form a liner, followed by grouting of the annulus.
    (d) Deformed pipe lining: a continuous deformed pipe which reverts to its predeformed
    shape after installation.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 11: Sewer Rehabilitation

    (e) Pipe cracking or bursting: replacement of an existing pipeline between manholes or


    inspection chambers or a combination thereof with a new pipe of equivalent or
    greater size whereby the new pipe is inserted behind the pipe breaking machine as
    fragments of the existing pipe are displaced to the sides.
    (f) Length of sewer: length of sewer pipe between two consecutive manholes or
    inspection chambers.
    (g) Service connection: the connection of the property sewer with the main sewer pipeline.

    11.1.4 Submittals

    1 The Contractor shall submit complete data and details of sewer rehabilitation for the
    Engineers approval as follows:

    (a) name and experience of specialist subcontractor

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    (b) a programme of work, detailed method statement, and schedule of plant to be used in

    .l.
    the Works, detailing the working practices, and specialist equipment.

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    (c) proposed method of overpumping or flow diversion as applicable to undertake sewer
    rehabilitation.
    (d)
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    specific data for proposed materials and equipment for the Engineers approval 14
    days prior to commencement of any sewer rehabilitation works as follows:
    qa
    (i) test certificates and technical literature to show that the sealants, liners, and
    lining systems materials proposed meet the requirements stated in the
    as

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


    (e) Specific data to be submitted while carrying out and at the completion of the work:
    ov

    (i) records of sealing of sewers in each length of sewer, including joint sealing
    verification results
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    (ii) CCTV video tapes, pictures in digital format (TIFF) and site coding sheets
    et

    prepared in accordance with Part 10 of this Section showing the initial condition
    and the completed work including the restored condition.
    m

    (f) The Contractor shall submit to the Engineer following data for 15 sewer rehabilitation
    projects carried out by the proposed subcontractor during the last five years:
    (i) project location
    (ii) name and address of client
    (iii) start and completion dates
    (iv) cost of the works
    (v) length, diameter and material of pre-rehabilitated sewers
    (vi) length, diameter and liner material for each type of rehabilitation system
    (vii) reference letter from the client or the engineer.
    QCS 2014 Section 08: Drainage Works Page 7
    Part 11: Sewer Rehabilitation

    2 The Contractor shall submit the following data to supplement (d) of this sub-clause:

    (a) Sewer Liner


    (i) Manufacturers name.
    (ii) Suppliers name.
    (iii) Installers name (Subcontractor)
    (iv) Product name (if applicable).
    (v) Product description.
    (vi) Manufacturers technical data.
    (vii) Test results or certificates.
    (viii) Checked and approved liner pipe thickness design and stiffness calculations.

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    (ix) Storage instructions.

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    (x) Installation instructions.

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    (xi) Installation records in the same project area

    (b)
    (xii)
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    Proposed grout mixture where applicable.
    Manhole and joint sealing materials and manhole rehabilitation materials
    qa
    (i) Manufacturers name.
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    (ii) Suppliers name.


    (iii) Installer name (Subcontractor)
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    (iv) Product name (if applicable).


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    (v) Product description.


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    (vi) Manufacturers technical data.


    (vii) Test results or certificates.
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    (viii) Storage instructions.


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    (ix) Application instructions.


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    3 The Contractor shall submit method statements to the Engineer for approval 4 weeks in
    m

    advance of commencing the site activity. These shall comprise but not necessarily be limited
    to:

    (a) Sewage bypass pumping and/or diversion plan which shall include an emergency
    response plan to be followed in the event of a failure of the bypass pumping and/or
    diversion plan.
    (b) Detailed construction plan including:
    (i) Equipment set-up and locations of proposed access points.
    (ii) Anticipated cut off periods for services.
    (iii) Procedures for verification of active service connections.
    (iv) Procedures for notifying affected residences and businesses.
    (v) Procedures for complying with traffic control.
    (vi) Procedures to be adopted to obtain permits to work from the Drainage Affairs.
    QCS 2014 Section 08: Drainage Works Page 8
    Part 11: Sewer Rehabilitation

    (vii) Safety procedures in particular working with scaffolding, entering confined


    spaces and operations with hot media.
    (viii) Sewer cleaning procedures.
    (ix) Liner installation procedures.
    (x) Procedures for sealing annular space between liner pipe and host pipe where
    applicable.
    (xi) Methods of sealing any annular space between liner pipe and host pipe at
    manholes.
    (xii) Procedures for manhole liner-pipe liner joint sealing.
    (xiii) Procedures for manhole rehabilitation.
    (xiv) Procedure for any required modifications (temporary or permanent) to existing

    .
    manholes (such as widening of access opening, removal of cover slabs,

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    removal of intermediate landings, ladders, removal of manholes benching etc).

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    4 The Contractor shall submit drawings to the Engineer for approval in advance of
    commencing the site activity. These shall comprise but not necessarily be limited to:

    (a) Liner insertion locations.


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    qa
    (b) Sewage bypass pumping and/or diversion locations.
    (c) Liner end sealing at manholes and GRP lamination to manhole wall and benching
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    liners.
    (d) Any required modification to existing manholes.
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    5 Representative samples, as agreed with the Engineer, must be submitted for at least the
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    following items before work commences.


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    (a) Proposed liner system.


    (b) Liner to host pipe sealing materials.
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    (c) Manhole rehabilitation materials.


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    (d) Manhole liner to pipe liner sealing materials.


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    11.1.5 Quality Assurance


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    1 The system shall be design to comply with the appropriate provisions of BS 2782, BS 3412,
    BS 5556, BS EN 752 and BS 8010.

    2 The Contractor shall employ approved prequalified specialist subcontractors designated in


    the Project Specification.

    3 The specialist subcontractor shall conduct this work in accordance with the quality
    management procedures conforming to ISO 9000.

    4 Key operators employed of the subcontractor shall be competent in the relevant sewer
    rehabilitation methods and techniques.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 11: Sewer Rehabilitation

    11.1.6 Warranty

    1 The Contractor shall provide the Engineer with a seven year unconditional warranty against
    failure of all GRP manhole linings whether caused by defective materials or workmanship.
    The warranty shall be valid from the date of completion of the installation and submitted to
    the Engineer as a precondition to the issuance of the Certificate of Completion.

    11.2 GENERAL REQUIREMENTS

    11.2.1 Work Programme Review, Cleaning, Inspection

    1 When designated in the Project Specification, the Contractor shall allow in his programme of
    work for the requirement that he shall work at many locations at any one time. However, at
    least one team shall be fully engaged on each length of sewer, and shall finish all

    .
    rehabilitation works required on that length of sewer including manholes and chambers

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    .l.
    before beginning work on a new length of sewer.

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    2 The Contractor shall provide methods statements for each of the rehabilitation methods and
    systems he proposes to use for each of the functional requirements designated in the Project
    Specification.
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    qa
    3 As cleaning and inspection work proceeds, the Contractor shall submit weekly sewer and
    manhole condition reports to the Engineer. In the reports, the Contractor shall include his
    confirmation that his proposed method of rehabilitation meets the required performance
    as

    criteria. Should the originally proposed method not meets the performance requirements for
    lengths of sewer, or manholes, the Contractor shall submit his proposals to meet the
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    performance requirements for such lengths of sewers or manholes to the Engineer for
    approval.
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    4 The Engineer and the Contractor shall agree on the locations and systems to be used for
    ov

    rehabilitation if necessary, and if necessary the Contractor shall review and revise his
    programme of work and submit to the Engineer for approval. The Engineers approval shall
    not relieve the Contractor of his obligations under the Contract.
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    5 Sewer cleaning, inspection and overpumping work shall be satisfactorily completed before
    et

    undertaking sewer rehabilitation.


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    11.2.2 Safety

    1 The Contractor shall carry out all operations in accordance with the safety requirements
    specified in Section 1 and Part 10 of this Section.

    11.2.3 Preparation for Installation of Linings

    1 The following installation procedures shall be adhered to unless approved otherwise by the
    Engineer:

    (a) before installing lining in sewers the Contractor shall ensure that the sewers are clean
    of debris in accordance with Part 10 of this Section. Sewers shall also be gauged to
    ensure that they can accommodate the liners.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 11: Sewer Rehabilitation

    (b) the Contractor shall inspect by CCTV the section or sections to be lined and shall
    record salient features including any obstructions and service connections, in
    accordance with Part 10 of this Section.
    (c) the Contractor shall overpump the sewage flow around the section or sections of the
    pipeline that are to be lined. The overpumping shall be carried at in accordance with
    Part 10 of this Section. Leaks in the pipes due to groundwater infiltration shall be
    stopped by grouting or other appropriate methods approved by the Engineer.
    (d) the Contractor shall clear the pipeline of obstructions, solids, dropped joints, or tree
    roots or collapsed pipe that will prevent the insertion of the liner. Where inspection or
    gauging reveals an obstruction that is not at the location of the entry shaft, the
    Contractor shall remove the obstruction by means of a cutting machine inserted into
    the sewer line. Where this is not possible, the Contractor shall make an excavation to
    expose and remove or repair the obstruction as directed by the Engineer.

    .
    (e) a temporary tie-in shall be made between the relined section and the existing system

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    .l.
    and the bypass plug removed at the end of each working day.

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    (f) Prior to dispatch of any product and/or material from source the Contractor shall notify
    the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect
    and test the product and/or material prior to delivery.
    (g) ta
    To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
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    minimum of 24 hours notice of carrying out the following activities on site.
    (i) Sewer cleaning.
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    (ii) CCTV survey.


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    (iii) Sewage bypass pumping and/or diversion.


    (iv) Liner installation.
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    (v) Manhole rehabilitation.


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    (h) No lining work shall be permitted until the prepared sewer has been inspected and
    approved by the Engineer.
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    (i) Where it is necessary to carry out any modification to existing manholes to enable
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    manhole and/or sewer cleansing, CCTV survey or sewer rehabilitation, the Contractor
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    shall carry out any such modification to the Engineers approval. Following completion
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    of the works in a manhole, the Contractor shall return the manhole to its original or
    better condition to the approval of the Engineer including reinstatement to surfaces
    disturbed as a result of manhole modification/sewer rehabilitation. Modification to
    manhole may include removal of manhole cover slab, intermediate landing slabs,
    platforms and manhole benching. Removal of intermediate landing slabs/platforms
    may be considered as permanent (i.e. may not necessarily be reinstated) provided the
    GRP wall liner is extended to cover the exposed area due to slab removal and welded
    to the existing liner, and the GRP ladder is adjusted and re-installed as a continuous
    ladder throughout the manhole height.
    (j) Unless specifically itemised and listed in the BOQ, modifications to manholes which
    may be necessary to carry out the sewer rehabilitation and associated works shall be
    deemed to be included in the sewer rehabilitation rates.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 11: Sewer Rehabilitation

    11.2.4 Delivery, Storage and Handling

    1 Delivery, storage and handling of products and materials shall be in accordance with the
    manufacturers recommendations and the following provisions.

    (a) Delivery storage and handling shall at all times be performed in a manner to avoid
    product damage.
    (b) The liner shall not come in contact with any sharp projections that may cause damage
    during transportation loading and unloading. Cover liner during transportation.
    (c) Store materials on a flat level area and raised above the ground on timber bearers.
    (d) Store materials under opaque cover and out of direct sunlight at all times. Maintain a
    free flow of air around materials at all times.
    (e) The Contractor shall visually inspect all products upon delivery to site and report any

    .
    damage to the Engineer.

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    2 Any products damaged during delivery, storage and handling shall be marked by the

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    Contractor and set aside.

    3
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    Proposals for repair of any damaged products shall be submitted in writing to the Engineer
    for approval.
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    4 Any damaged products deemed unsuitable for repair by the Engineer shall be removed from
    site and replaced.
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    11.2.5 Annulus Grout


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    1 Low strength grout filling the annular space between the host pipe and the liner (where
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    applicable) shall be a cementitious mixture incorporating suitable admixtures as approved by


    2
    the Engineer and shall have a minimum compressive strength of 12N/mm .
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    2 Generally, the equipment shall be capable of performing the specified operations in lines
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    where flows do not exceed the maximum line flows for joint testing/sealing.
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    11.3 SEALING OF PIPES AND MANHOLES


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    11.3.1 Scope

    1 Complete or an initial step of rehabilitation by the remote sealing of sewer pipe joints using a
    sealing packer. The materials specified herein shall also be applicable in sealing of man-
    access sewers and manholes.

    11.3.2 Sealing Compounds

    1 The sealing material shall comply with BS 2494 and shall perform effectively in the intended
    application and under expected field conditions.

    2 Mixing and handling of sealing materials shall be in accordance with the manufacturers
    recommendations.
    QCS 2014 Section 08: Drainage Works Page 12
    Part 11: Sewer Rehabilitation

    3 Chemical sealing compounds shall have the following properties and characteristics:

    (a) while being injected, the chemical sealant shall be able to react/perform in the
    presence of either, or both, surface water or groundwater, if present
    (b) the cured material shall withstand submergence in either, or any combination of,
    surface water, groundwater, sea water or sewage without degradation
    (c) the resultant sealant formation shall prevent the passage of water through the sewer
    pipe joint
    (d) the sealant material, after curing, shall be flexible
    (e) in place, the formed sealant shall be able to withstand wet/dry cycles without
    adversely affecting the seal
    (f) the formed sealant shall be non-biodegradable

    .
    (g) the cured sealant shall be chemically stable and resistant to the chemical constituents

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    .l.
    sewage and the sewer environment

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    (h) packaging of component materials shall
    (i) be compatible with site storage and handling requirements
    (ii) ensure worker safety
    ta
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    (iii) cause minimal spillage during handling
    (i) mixing of the component materials shall be compatible with field operations
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    (j) cleanup shall be effected without inordinate use of flammable or hazardous chemicals
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    (k) residual sealing materials shall be removed from the sewer to prevent any blockage of
    the sewage flow.
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    4 Chemical resin for sealing pipe joints and manholes shall be a hydrophilic polyurethane
    ov

    compound suitable for injection.

    5 The material must be salt-water grade, able to react with saline ground water to form a
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    flexible seal.
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    et

    11.3.3 Joint Sealing of Pipes


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

    2 The sealing equipment shall comprise a CCTV survey system, chemical sealant containers,
    pumps, regulators, injection sealing packers, hoses, valves and all other necessary
    apparatus and tools required for sealing sewers of the various diameters. The packer shall
    be cylindrical and shall be so sized and have cables attached at each end to enable it to be
    pulled freely through the pipeline. The packer device shall be constructed in a manner to
    allow an amount of sewage to flow as designated in the Project Specification.
    QCS 2014 Section 08: Drainage Works Page 13
    Part 11: Sewer Rehabilitation

    3 Joint shall be sealed by injecting chemical sealing compound into or through faulty joints
    using a system of pumps, hoses, and sealing packers. Jetting or driving pipes from the
    surface that could damage the pipelines or impair their structural integrity will not be
    permitted. Uncovering the pipe by excavation of pavement and soil will not be allowed. The
    packer shall be positioned over the faulty joint by means of a measuring device and the
    CCTV camera in the pipeline. The Contractor shall ensure that the packer is accurately
    positioned over the joint. The packer ends shall be expanded using controlled pressure. The
    expanded ends shall seal against the inside periphery of the pipe to form a void area at the
    faulty joint which shall be completely isolated from the remainder of the pipeline. Sealant
    compound shall be pumped into the isolated area through the hose system at controlled
    pressures in excess of groundwater pressure, if any.

    4 Upon completing sealing of each joint, the packer shall be completely deflated then reinflated
    and the joint retested. Should the void pressure meter not read zero after deflation, the
    Contractor shall clean his equipment of residual grout material or make the necessary

    l .
    equipment repairs/adjustments to produce accurate void pressure readings. Joints that fail to

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    meet the specified test criteria shall be resealed and retested until the test criteria can be

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    met.

    5 Residual sealing materials protruding into the pipe shall be removed. The sealed joints shall

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    be left flush with the pipe surface. Excessive residual sealing materials which accumulate in
    qa
    the pipeline shall be removed.

    6 Records shall be kept of joints sealing performed in each length of sewer to identify the
    as

    length of sewer in which joints were, the location of each joint sealed, and the joint sealing
    verification test results.
    se

    7 Not more than one month before the expiration of the Period of Maintenance and as a
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    precondition to the Engineers issuance of the Maintenance Certificate for the Contract,
    sewers shall be retested as follows:
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    (a) an initial retest area consisting of specific lengths of sewers will be selected by the
    Engineer. Length of sewers to be retested shall be randomly selected throughout the
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    project area and shall be representative of the majority of the sealing work originally
    it

    performed. The initial retest area shall consist of at least 5 %, but not exceed 10 %, of
    et

    the length contained in the Contract


    m

    (b) within the initial retest area, the Contractor shall retest all previously sealed joints as
    specified. Any joints failing the retest shall be resealed at no extra cost to the Employer
    (c) if the failure rate of the joints exceeds 5 % of the retested joints, an additional retest
    area of equivalent size will be selected by the Engineer and all previously sealed
    joints shall be retested. The additional testing and sealing, where necessary, shall
    continue until a failure rate of less than 5 % is achieved
    (d) additional testing or sealing required beyond the initial retest area shall be
    accomplished at the Contractors expense. The Contractor shall provide adequate
    number of crews at Site so that the retesting will proceed at a rapid rate.

    8 The pumping unit, metering equipment and the packer device shall be designed so that
    proportions and quantities of materials can be regulated in accordance with the type and size
    of the leak being sealed.
    QCS 2014 Section 08: Drainage Works Page 14
    Part 11: Sewer Rehabilitation

    11.3.4 Sealing of Manholes

    1 During cleaning and inspection work the condition of manholes shall be observed and their
    structural soundness shall be evaluated by the Contractor and reported in the cleaning and
    inspection reports. Sealing work shall only be carried out on manholes which the Engineer
    considers structurally sound and which experience extraneous water leakage.

    2 Cracks and openings to be sealed shall be marked out in detail on the concrete elements by
    the Contractor and agreed with the Engineer before proceeding with sealing operations.

    3 Sealing equipment shall consist of chemical sealant containers, pumps, regulators, injection
    packers, hoses, valves, and all other necessary apparatus and tools. The chemical injection
    pumps shall be equipped with pressure meters for monitoring pressure during the injection of
    the chemical sealants. Where necessary, fluid bypass lines equipped with pressure-
    regulated bypass valves shall be incorporated into the pumping system.

    l .
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    4 Structural cracks shall be repaired out as follows:

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    (a) holes shall be carefully drilled close to the damaged section from within the manhole
    and shall extend through the entire manhole wall
    (b)
    ta
    if leakage is occurring through cracks due to high groundwater table, fewer holes shall
    qa
    be drilled provided all leakage is stopped from these holes. A watertight seal between
    the holes and the injection device shall be provided. Hoses, shall be attached to the
    injection device from an injection pump. Chemical sealing materials shall then be
    as

    pumped through the hose until material refusal is recorded on the pressure gauge
    mounted on the pumping unit or a predetermined quantity of sealant has been injected
    se

    (c) care shall be exercised during the pumping operation to ensure that excessive
    pressures do not develop and causing damage to the manhole structure
    er

    (d) upon completion of the injection, the packers shall be removed and the remaining
    ov

    holes filled with mortar and trowelled flush with the surface of the manhole walls or
    other surfaces
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    (e) the mortar used shall be of the quick-setting type with non-shrinking characteristics
    it

    (f) any GRP internal lining which has been disturbed shall be repaired in accordance with
    et

    Part 7 of this Section.


    m

    5 Not more than one month before the expiration of the Period of Maintenance and as a
    precondition to the Engineers issuance of the Maintenance Certificate for the Contract,
    manholes shall be visually inspected by the Contractor in the presence of the Engineer.
    Sealing work that has become defective shall be repaired at no additional cost to the
    Employer.

    6 All manhole sealing shall be done during high groundwater conditions, unless the points of
    leakage have been previously identified.
    QCS 2014 Section 08: Drainage Works Page 15
    Part 11: Sewer Rehabilitation

    11.4 SLIPLINING OF SEWERS

    11.4.1 General

    1 The scope of work consists of rehabilitating sewers by the insertion of liner pipe into existing
    sewers. The finished liner shall extend the full distance detailed in the project specific
    documentation, which may be for localised repair, or extend the full sewer length. In either
    case the lining shall be completely sealed and watertight.

    2 Procedures set out in ASTM F 585 shall be followed, except as otherwise specified in this
    Part.

    3 The Contractor is not constrained on the type of lining method he puts forward, but the
    Contractor will have to demonstrate, through previous project documentation, that the

    .
    proposed method has a proven track record and that it is fully applicable to the conditions to

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    be found in the Gulf region.

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    4 The Contractor shall design the liner to support all combinations of imposed loads including
    earth, traffic, hydrostatic etc and have a minimum service life of 50 years. For the purpose of
    calculations, it shall be assumed the ground water table is at ground level. Host pipes shall

    ta
    be considered to be fully deteriorated. The liner shall have a minimum allowable long term
    qa
    2
    stiffness of 2500N/m and be designed to have a factor of safety of 2.

    5 The normal requirement will be that the liner shall provide the least possible thickness or
    as

    decrease in diameter to meet the requirements of this section and consequently it is


    preferable to be of the close fit type.
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    6 Liner shall be of a light colour to enhance Closed Circuit Television (CCTV) clarity for
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    inspection purposes.
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    7 Leak repair shall be carried out when required to create an environment to enable the
    rehabilitation works to be executed successfully. If the rehabilitation method adopted can be
    successfully implemented under wet conditions, the Contractor is not obliged to repair the
    o

    leaks.
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    8 The finished liner shall be continuous over the entire length of an insertion run between two
    m

    manholes or access points and shall be free from visual defects.

    9 The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to
    manhole liner using a material that is compatible with the liner.

    11.4.2 Materials

    1 The sewer liner pipe and fittings shall be manufactured from a polyethylene compound
    conforming to ASTM D1248 and meeting the requirements for Type II or III, Class B or C,
    Grades P23 or P34, Category 5. Pipe made from this compound shall have a minimum long-
    term hydrostatic strength rating of 8.6 MPa in accordance with ASTM D2837. When the
    environmental stress crack resistance (ESCR) of the compound is measured in accordance
    with ASTM D1693, Condition C, the compound shall withstand not less than 192h in 100 %
    solution Igepal CO-630 at 38 C before reaching a 20 % failure point (F20).
    QCS 2014 Section 08: Drainage Works Page 16
    Part 11: Sewer Rehabilitation

    2 The standard dimension ration (SDR), defined as the specified outside diameter (OD) divided
    by the minimum wall thickness, shall be demonstrated by calculation to be sufficient to
    support the worst combination of internal and external loads. The wall thickness tolerance
    shall be within plus 12 %.

    3 Liner pipe shall be provided with joints designed so that neither the outside diameter of the
    pipe is increased nor the internal diameter of the pipe is decreased at the joint.

    0
    4 Liner pipes shall be suitable for use in ambient air temperatures up to 55 C and with sewage
    0
    up to 45 C.

    11.4.3 Installation of Sliplining

    1 Where excavations for insertion of liner are made, the Contractor shall locate the excavations
    on the basis of the location of the sewers to be sliplined, pulling distances, and traffic

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    conditions subject to Engineers approval. Excavation locations shall be such as to minimise

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    traffic disruption, and the number of excavations reduced by inserting the pipe in both

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    directions from a single opening. Insertion shafts shall be designed to avoid imposing a
    bending radius of less than 35 times the outside diameter of the liner. Insertion shafts shall
    be sloped gradually from the ground surface to the soffit of the sewer. The Contractor shall

    ta
    provide sufficient sheeting and bracing to the excavation as required. The soffit of the
    qa
    existing sewer shall be exposed and the crown of the pipe shall be removed as necessary for
    insertion of the liner. Care shall be taken not to disturb the bottom portion of the existing
    pipe.
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    2 Jointing shall be by thermal butt-fusion welding in accordance with the manufacturers


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    recommendations. All fusion jointing shall be carried out by trained personnel with equipment
    designed for butt-fusion welding of thermoplastic pipe.
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    3 Sections of liner shall be jointed above ground either at the Site or at a remote location.
    ov

    4 Where the insertion shaft is not at a manhole the jointing shall be accomplished using a
    stainless steel full-encirclement clamp. If such jointing cannot be achieved, then a new
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    manhole shall be constructed. Recommended minimum lengths of clamps to afford adequate


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    pullout protection are given in Table 11.1.


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    Table 11.1
    Minimum Length of Clamps

    OD of Liner Pipe Minimum Length of Clamp

    (mm) (mm)
    90 190
    115 250
    135 250
    170 380
    180 380
    220 380
    270 500
    QCS 2014 Section 08: Drainage Works Page 17
    Part 11: Sewer Rehabilitation

    OD of Liner Pipe Minimum Length of Clamp

    325 500
    340 500
    405 760
    455 760
    475 760
    560 760
    661 760

    5 Alternative pipe jointing methods shall be subject to the approval of the Engineer.

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    6 The liner shall be inserted with a power winch and steel cable connected to the end of the

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    liner using of an appropriate pulling head. Where necessary a second pulling head may be
    attached to the other end of the liner for attachment of a tag line to pull the liner back out of
    the sewer.

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    Pulling shall be continued form start to completion without interruption, and precautions shall
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    be taken during insertion to protect the liner pipe so that any ragged edges of a broken sewer
    pipe will not score the outside of the liner.
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    8 The manufacturers recommendations regarding relaxation of the liner shall be followed


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    before sealing the annular space between the liner and existing sewer pipe. The annular
    space between the polyethylene liner and the existing sewer shall be sealed using a method
    approved by the Engineer.
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    9 Where an existing manhole is used as an entrance shaft the manhole shall be reinstated to
    good condition or it shall be replaced with a new manhole in accordance with Part 4 of this
    Section.
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    10 Foam sealant shall not protrude into the manhole and the sealant shall be finished over with
    et

    a quick-setting, non-shrinking type of cement grout. Finishing inside the manhole shall be
    accomplished using a quick-setting cement type grout to raise the manhole trough to the
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    invert of the liner pipe and reform the manhole benching as required. Exposed cement type
    grout surfaces shall be protected against corrosion by lining with GRP in accordance with
    Clause 4.4.1 of this Section.

    11 Precautions shall be taken to prevent collapsing of the liner owing to excessive grouting
    pressure.

    12 The liner shall be secured in the upstream manhole. Each existing service connection shall
    be excavated and reconnected to the new liner pipe using either polyethylene heat fusion
    saddles or strap-on saddles as conditions require. A neoprene gasket shall be inserted
    between the liner and the strap-on saddle. Saddles shall be secured to the liner pipe using
    stainless steel bands. Connections of saddle fittings to existing service connections shall be
    made using elastomeric boots, full-encirclement clamps, or other methods approved by the
    Engineer.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 11: Sewer Rehabilitation

    13 Before backfilling any existing sewers that had been broken to open, the pipe shall be
    repaired and the annular space between the existing sewer and the new liner sealed using
    cement or expandable foam to the approval of the Engineer.

    14 At locations where the liner pipe has been exposed, the pipe and fittings shall be encased in
    Grade 20 SRC concrete.

    11.5 DEFORMED PIPE LINER INSTALLATION

    11.5.1 Scope

    1 The scope of the work consists of rehabilitating sewers by the insertion of a deformed
    thermoplastic pipe into existing sewers. The deformed pipe on the application of pressure
    and temperature or on release of deforming stress induced by swaging reverts to its pre-

    .
    deformed shape to form a tight fit inside the host pipe without the formation of an annulus.

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    11.5.2 Materials

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    1 The HDPE liner material shall be designed for use in gravity sewers and shall be in strict
    conformance with all applicable sections of ASTM F1533.

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    2 The liner shall be made from High Density Polyethylene resins complying with ASTM D1248,
    Type III, Grade P34 and Cell Classification PE 345434C, D or E per ASTM D3350. The
    Contractor shall submit to the Engineer for approval certified test results from the liner pipe
    as

    manufacturer to verify that the resin material used for extrusions of the liner meets the
    specified requirements, including the quality control records during the liner extrusion
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    process.
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    3 At the time of manufacture, each lot of liner shall be inspected for defects with samples being
    taken in accordance with ASTM D4703 and tested in accordance with ASTM D1693, ASTM
    ov

    D2837 and ASTM F714.

    4 For testing purposes a production lot shall consist of all liner having the same marking
    o

    number. It shall include all items produced during any given work shift and must be identified
    it

    accordingly to differentiate it from previous or following production.


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    5 Each deformed liner coil in compliance with ASTM F1533 shall be clearly marked by the
    manufacturer with the following information:

    (a) ASTM F1533 designation.


    (b) Nominal outside diameter.
    (c) SDR.
    (d) Approximate coil length.
    (e) Standard material designation code.
    (f) Manufacturers name.
    (g) Manufacturers production code from which plant location, machine and date of
    manufacture can be identified.
    (h) The project or contract number.
    QCS 2014 Section 08: Drainage Works Page 19
    Part 11: Sewer Rehabilitation

    6 Liner minimum wall thickness shall be determined by strength and minimum stiffness
    requirements.

    7 The liner shall be fabricated from materials which will be resistant to internal exposure to
    sewage, sewage gases and reagents listed in Table 1 above, when tested in accordance with
    the provisions of ASTM D543, to a temperature of 40C.

    8 The HDPE material used in the production of the liner shall meet, or exceed, the physical
    properties given in Table 11.5 below.
    Table 11.5
    Deformed Pipe Liner Properties
    Property Test Method Value

    3
    Density ASTM D1505 950kg/m

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    Flow rate ASTM D1238 8.0g/10min

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    2
    Tensile strength @ ultimate ASTM D638 30N/mm
    2
    Tensile strength @yield ASTM D638 20N/mm

    Ultimate elongation ASTM D638


    ta 600%
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    2
    Flexural modulus ASTM D790 1000N/mm
    Environmental stress crack
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    resistance
    ASTM D1693 10,000 hrs
    F0, hours condition C
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    ASTM F1248 10,000 hrs


    Compressed ring ESCR F0
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    0
    Brittleness temperature ASTM D746 -117 C
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    0
    Vicat softening temperature ASTM D1525 125 C

    Hardness, Shore D ASTM D2240 50


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    15
    Volume resistivity ASTM D991 10 ohm-cm
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    et

    0
    Thermal expansion 0.20mm/m/ C
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    9 At the time of installation the liner shall be homogeneous throughout, uniform in colour, free
    of cracks, holes, foreign materials, blisters and deleterious faults.

    11.5.3 Installation

    1 The Contractors method statement shall be submitted to the Engineer for approval. In the
    method statement the Contractor shall describe the means of deforming the liner in-situ and
    of providing, maintaining, monitoring, and controlling the reforming environment until the liner
    has reverted to its original circular shape and the temperature returns to the normal sewer
    ambient temperature.

    2 Calculations demonstrating the adequacy of the pulling capacity of the winch shall be
    prepared and submitted by the Contractor for the Engineers approval.
    QCS 2014 Section 08: Drainage Works Page 20
    Part 11: Sewer Rehabilitation

    3 The liner shall be positioned at the upstream manhole without excavation and shall be
    winched directly from the coil through the upstream manhole and the host pipe.

    4 Due care shall be exercised during winching to avoid damage to manholes and snagging.
    Guides or rollers shall be used within the manholes to avoid the risk of snagging.

    5 The pulling winch shall be equipped with a tension gauge capable of controlled operation at
    variable speed.

    6 The pipe shall be cut flush at manhole inlet and outlet points using a rotary cutter and the
    joints sealed.

    7 The Contractor shall adopt working practices for plastic pipes accordance with BS 5955.

    8 The Contractor shall obtain detailed installation instructions and procedures from the

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    manufacturer for the actual installation of the deformed and reformed system. The

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    requirements of ASTM F1606 shall also be satisfied.

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    9 When the deformed pipe liner is in place it shall be cut and the pipe end closing assembly
    used for heat and pressure control within the liner shall be attached and secured at both pipe

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    ends. Temperature and pressure measuring instruments shall be attached to both ends of
    the deformed HDPE liner to provide a continuous monitor of the temperature and pressure
    qa
    being applied to the liner.
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    10 Through the use of steam and air pressure the deformed pipe shall be reformed to conform
    to the existing pipe wall.
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    11 The reformed HDPE liner shall be cooled in accordance with the manufacturer
    recommendations.
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    12 Temperatures and pressures shall be monitored and recorded throughout the installation
    process to ensure that each phase of the process is achieved at the manufacturers
    recommended temperature and pressure limits
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    13 For each length of liner two samples shall be taken at locations determined by the Engineer.
    et

    The sampling method shall include the use of a former to replicate the host pipe. The
    samples shall be clearly labelled with date taken and location. The samples shall be tested
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    for average inside diameter, average outside diameter and minimum wall thickness in
    accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
    D2412 and for the properties given in Table 3. The stiffness so measured shall meet, or
    exceed the stiffness requirements determined by calculation for that section of sewer line or
    the minimum specified stiffness whichever is greater. Any material may be rejected for failing
    to meet any of the requirements of this specification.

    14 The water tightness of the liner shall be gauged throughout the forming process.

    11.6 CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD)

    11.6.1 Scope

    1 The scope of work consists of rehabilitating sewers by the installation of a resin impregnated
    flexible felt tube inverted into existing sewers. When cured, the new material shall extend
    over the length of the inversion as a continuous, tight-fitting, watertight lining.
    QCS 2014 Section 08: Drainage Works Page 21
    Part 11: Sewer Rehabilitation

    11.6.2 Materials

    1 The liner material shall be designed for use in gravity sewers and shall be in strict
    conformance with all applicable sections of ASTM F1216.

    2 The felt liner tube shall be a thermoplastic polyester tube consisting of one or more layers of
    flexible needled felt or an equivalent woven and/or non/woven material capable of carrying
    resin, and with sufficient needling and crosslapping and strength to withstand the installation
    pressures and curing temperatures.

    3 The felt tube shall be compatible with the resin and catalyst systems to be utilised.

    4 The finished liner shall consist of a felt layer (or layers) impregnated with a thermosetting
    resin and fabricated to fit tight against the host pipe. An allowance shall be made for
    circumferential stretching during installation where applicable.

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    5 Each felt liner tube shall be clearly marked by the manufacturer with the following

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    information:

    (a) Manufacturers name.


    (b)
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    Manufacturers production code from which plant location, machine and date of
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    manufacture can be identified.
    (c) The project or contract number.
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    6 The lining technique shall comprise using a suitable preliner to prevent loss of resin.
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    7 The resin used shall be a general purpose, unsaturated, thermosetting, vinylester resin able
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    to cure in the presence or absence of water and a catalyst system compatible with the
    insertion process that provides physical properties given in Table 11.6.
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    Table 11.6
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    Cured in Place Liner Properties


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    et

    Property Test Method Value


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    2
    Flexural strength ASTM D790 31N/mm
    2
    Short term flexural modulus ASTM D790 1724N/mm
    2
    Long term flexural modulus ASTM D790 862N/mm
    2
    Tensile strength ASTM D638 21N/mm

    8 The installed and cured liner shall be chemically resistant to exposure to sewage and sewage
    gases as experienced with the high temperatures in Qatar.

    9 At the time of installation the liner shall be free of all visible tears, holes, cuts, foreign
    materials and other defects.
    QCS 2014 Section 08: Drainage Works Page 22
    Part 11: Sewer Rehabilitation

    10 The liner shall be fabricated to a size that when installed will neatly fit the internal
    circumference of the sewer being renovated. Allowance shall be made for circumferential
    stretching during insertion. The minimum length shall be that deemed necessary by the
    Contractor to effectively span the distance from inlet to outlet of the respective manholes
    unless otherwise designated in the contract specification. The Contractor shall verify the
    lengths on Site before impregnation. Individual inversion runs may be made over one or
    more lengths of sewer as determined on Site by the Contractor and approved by the
    Engineer.

    11.6.3 Installation of Cured-In-Place Liner

    1 The following installation procedure shall be adhered to unless otherwise proposed in the
    Contractors method statement and approved by the Engineer:

    (a) the Contractor shall designate a location or locations where the reconstruction tube will

    l .
    be vacuum impregnated before installation. The Contractor shall allow the

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    Engineer to inspect the materials and wet-out procedure. A catalyst system

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    compatible with the resin and reconstruction tube shall be used
    (b) the Contractor shall provide facilities to control the temperature of the wet-out
    reconstruction tube to prevent premature setting of the resin
    (c) ta
    the wet-out reconstruction tube shall be inserted through an existing manhole or
    qa
    other approved access by means of an inversion process and the application of an
    inversion medium of sufficient pressure and volume sufficient to fully extend it to the
    as

    designated or termination point


    (d) the inversion pressure shall be adjusted to be sufficient to cause the
    se

    impregnated tube to invert from manhole to manhole and hold the tube tight to the
    pipe wall and to produce dimples at side connections and flared ends at the
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    manholes. Care shall be taken during the elevated curing temperature so as not to
    overstress the felt fibre
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    (e) after inversion is complete, the Contractor shall provide a suitable curing
    environment. Monitoring and control equipment shall be provided to permit
    o

    observation and maintenance of the curing environment. Temperature and other


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    factors of the curing environment shall be those recommended by the resin


    et

    manufacturer
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    (f) should excessive infiltration into the sewer be present, a preliner shall be inserted
    into the sewer line to prevent washout of the resin.

    2 Initial curing shall be deemed to be completed when inspection of the exposed portions of
    cured pipe appear to be hard and sound and the remote temperature sensor indicates that
    the temperature is of a magnitude to realise an exotherm. The curing period shall be that
    recommended by the resin manufacturer, as modified for the cured-in-place inversion
    process, during which time the Contractor shall maintain the quality of the curing environment
    to the levels recommended by the resin manufacturer.

    3 The Contractor shall cool the hardened liner to a temperature below 38 C before relieving
    the pressure. Cooling may be accomplished by the introduction of cool water into the
    inversion standpipe to replace water being drained from a small hole made in the
    downstream end. Care shall be taken in the release of the static head so that a vacuum will
    not be developed that could damage the newly installed liner.
    QCS 2014 Section 08: Drainage Works Page 23
    Part 11: Sewer Rehabilitation

    4 Where the new liner fails to make a tight seal due to broken or misaligned host pipe at the
    manhole wall, the Contractor shall apply a seal at that point. The seal shall be of a resin
    mixture compatible with the liner and the host pipe.

    5 After the new liner has been cured in place, the Contractor shall reconnect existing active
    service connections as directed by the Engineer. Unless otherwise designated in the contract
    specific documentation, shall be done without excavation. In the case of non -man-entry
    pipes from the interior of the system by means of CCTV cameras and a cutting devices that
    re-establish the service connection and seal the joint at the point of entry of the service
    connection.

    6 The Contractor shall obtain detailed installation instructions and procedures from the
    manufacturer for the actual installation of the cured in place liner system. The requirements
    of ASTM F1216 shall also be satisfied.

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    7 The section of pipeline to be lined shall have been cleaned, surveyed and repaired to the

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    requirements of this section of the standard specification prior to liner installation.

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    8 For each length of liner two samples shall be taken at locations determined by the Engineer.
    Sampling method shall include the use of a former to replicate the host pipe. The samples

    ta
    shall be clearly labelled with date taken and location. The samples shall be tested for
    qa
    average inside diameter, average outside diameter and minimum wall thickness in
    accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
    D2412 and for the properties given in Table 2. The stiffness so measured shall meet, or
    as

    exceed the stiffness requirements determined by calculation for that section of sewer line or
    the minimum specified stiffness whichever is greater. Any material may be rejected for failing
    se

    to meet any of the requirements of this specification.


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    9 The watertightness of the pipe shall be gauged while curing and under a positive head.
    ov

    10 The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to the
    manhole liner using a material that is compatible with the liner.
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    11 Wrinkles in the finished pipe which exceed 5% of the pipe diameter are unacceptable and the
    it

    liner shall be removed and a replacement liner installed to the approval of the Engineer.
    et

    11.7 SPIRAL WOUND PROFILE LINER


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    11.7.1 Scope

    1 The scope of work consists of rehabilitation of sewers by the installation of helically wound,
    profile walled thermoplastic pipe.

    11.7.2 Materials

    1 The physical properties of the PVC-U material used in the production of the liner shall
    conform to the cell classifications 12454C or 1236C, as defined by ASTM D1784.
    Notwithstanding this requirement, the material shall meet or exceed the following physical
    properties, as given in Table 11.2:
    QCS 2014 Section 08: Drainage Works Page 24
    Part 11: Sewer Rehabilitation

    Table 11.2
    Physical Properties of PVC-U Material

    Property Value

    Flexural Modulus (Short Term) 2400 MPa


    Flexural Modulus (Long Term) 800 MPa
    Tensile Strength (Short Term) 45 MPa
    Tensile Strength (Long Term) 20 MPa
    Heat Distortion Temperature 70 C
    Specific Gravity 1.4
    Allowable Long-term Strain 2%

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    Hardness (Shore D) 80

    rw
    2 The base material for the liner shall consist of a profile walled strip, extruded from PVC-U or

    ta
    other thermoplastic material, approved by the Engineer in accordance with ASTM F 1697. All
    materials shall be resistant to internal exposure to potable water, sea water, sewage, sewer
    qa
    gases, and reagents listed in Table 11.3, when tested in accordance with the provisions of
    ASTM D543, to a temperature of 35 C:
    as

    Table 11.3
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    Resistance of Liner Material


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    Reagent Concentration
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    Nitric Acid 5%
    Phosphoric Acid 10 %
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    Sulphuric Acid 10 %
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    Detergent 0.1 %
    Soap 0.1 %
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    3 Where high liner stiffness is required to resist external loads, the strength of the liner may be
    enhanced by the provision of plastic-coated stainless steel reinforcement wound into the liner
    at the time of installation. The steel reinforcement shall consist of stainless steel type 316L
    and shall be coated with a low density polyethylene coating or other material approved by the
    Engineer, not less than 1 mm thick. The steel shall meet or exceed the following physical
    properties given in Table 11.4:
    QCS 2014 Section 08: Drainage Works Page 25
    Part 11: Sewer Rehabilitation

    Table 11.4
    Physical Properties of Steel

    Property Value

    Tensile Strength 250 MPa


    Modulus of Elasticity 195 GPa
    9 x 10 / C
    -6
    Coefficient of thermal expansion

    4 For each length of liner a sample shall be prepared prior to the winding machine being placed
    into the manhole. A length of pipe shall be formed from the same batch of material to be
    used in the installation. The length of sample shall be such that three lengths may be cut and
    tested in accordance with ASTM D2412 for pipe stiffness at 5% deflection and for the
    properties given in Table 4. The stiffness so measured shall meet, or exceed the stiffness

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    requirements determined by calculation for that section of sewer line or the minimum

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    specified stiffness whichever is greater. Any material may be rejected for failure to meet any

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    of the requirements of this specification.

    5 Each liner shall be clearly marked by the manufacturer with the following information:
    Manufacturers name ta
    qa
    Manufacturers production code from which plant location, machine and date of manufacture
    can be identified
    as

    The project or contract number


    6 At the time of installation the liner shall be homogenous throughout, uniform in colour, free of
    se

    cracks, holes, foreign materials, blisters and deleterious faults.


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    7 This method may only be used for pipes of 250mm diameter or greater.
    ov

    11.7.3 Installation of Spiral Wound Profile Liner


    o

    1 The installation of spiral wound liner shall follow the recommendations of ASTM F-1698.
    it

    2 Spirally wound profile liners shall be installed using a winding machine placed at the bottom
    et

    of the manhole, with the liner being introduced at a diameter of approximately 25 mm less
    m

    than the minimum diameter of the pipeline to be rehabilitated. After the liner has been
    installed, the annular gap shall be filled with a cementitious grout or the liner shall be
    expanded until it comes into intimate contact with the host pipe.

    3 Jointing of the liner shall be accomplished by the use of an adhesive material suitable for use
    with the liner material. The adhesive shall be fully resistant to the corrosive sewer
    environment and shall be applied to the strips at temperatures of 35 to 50 C. Alternatively
    the liner shall be joined using a mechanical locking strip. The strip shall have mechanical and
    chemical resistance properties that are not less than those of the liner material. The joint
    shall be continuous and watertight for the full length of the sewer. The interface between the
    liner and manhole shall be sealed with material specified in Clause 11.10.3.
    QCS 2014 Section 08: Drainage Works Page 26
    Part 11: Sewer Rehabilitation

    4 Grouting of the annulus shall be carried out using the differential pressure method. The liner
    shall be filled with water and maintained at a constant pressure that is greater than the
    grouting pressure. Failure to maintain pressure in the pipeline will indicate that a defect
    exists. The water pressure shall be monitored via a gauge fitted to the grout plug, whereas
    the grouting pressure shall be monitored via a gauge fitted at the end of the grout hose.
    When water direct from a potable supply is used, an anti-siphon device shall be used to
    prevent contamination. Grouting shall be continued until there is a consistent flow of grout at
    the upstream manhole. Should grout pressure build up, before a show of grout is observed,
    the injection shall be stopped immediately to prevent damage to the liner. A sample of the
    grout shall be taken during grouting and its curing time monitored.

    5 Alternative grouting methods that are specific to a particular lining system will be allowed only
    with the approval of the Engineer.

    11.8 PIPE CRACKING OR BURSTING

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    11.8.1 Scope

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    1 Rehabilitation of sewers by the replacement of existing pipes with polyethylene (PE) or
    polypropylene (PP) pipes by breaking the existing pipes, expanding the hole size and
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    inserting the replacement pipes in one operation with a minimum of disturbance to the
    qa
    surrounding ground and no surface disruption.

    11.8.2 General
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    1 The Contractor shall satisfy the Engineer that the pipe bursting procedures will not have
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    detrimental effects on adjacent utilities or structures, particularly from vibration arising from
    use of pneumatic bursters. The Contractor shall be responsible for such damage and shall
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    bear the cost of rectification.


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    2 The Contractor shall comply with the requirements of service authorities and shall be
    deemed to have identified the location of services which may be affected by the Works.
    Unless otherwise required by the service authorities, where services are known to be located
    o

    within one meter of the pipe to be burst, the Contractor shall expose the service in advance
    it

    of pipe bursting. A minimum free space of 500 mm shall be created beneath the service over
    et

    a length to be agreed between the Contractor and the service authorities.


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    11.8.3 Materials

    1 The materials used for replacement of the existing pipes shall be polyethylene or
    polypropylene unless otherwise specified in the contract documents.

    2 The method of jointing the pipes shall be as the manufacturers recommendations for the
    application. Unless otherwise specified or approved by the Engineer pipe joints shall be
    designed to be watertight against external water pressure assuming that groundwater
    extends to the ground surface.
    QCS 2014 Section 08: Drainage Works Page 27
    Part 11: Sewer Rehabilitation

    11.8.4 Installation Equipment

    1 Pipe bursting equipment shall be hydraulically or pneumatically powered incorporating an


    expander at the nose of the machine which will fragment the existing pipe and expand the
    space uniformly to a diameter sufficient to allow the replacement pipe to be inserted. The
    annular space between the expander and the replacement pipe shall not exceed 20 mm
    unless otherwise agreed by the Engineer.

    2 The method of inserting the replacement pipe shall be such that stresses transmitted to the
    replacement pipe shall not damage the pipes or exceed the tensile capacity of the
    replacement pipe.

    3 Pipe bursting equipment shall be capable of

    (a) Working from existing manholes so that they can be used as launch and reception

    .
    shafts wherever possible. Provision shall be made for remote starting and stopping.

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    (b) Dealing with small quantities of unreinforced concrete of maximum 150 mm nominal

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    thickness found surrounding pipes, joints, saddles and service connections and for
    bursting pipes laid on a concrete cradle without being deflected off line and level.
    (c)
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    Working under a hydrostatic pressure of groundwater.
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    (d) Operating at maximum depth of 10.0 m from surface level.
    (e) Operation without jamming of moving parts or other malfunction due to the ingress of
    groundwater or sand particles.
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    4 Where the Contractor has not previously used the equipment or demonstrated the pipe
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    bursting technique to the satisfaction of the Engineer then he shall demonstrate the suitability
    of the equipment as follows:
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    (a) construct in open ground at a location approved by the Engineer, a 50m long
    ov

    temporary section of pipe of the same bore and material as the sewer to be
    rehabilitated at similar depth, complete with unbenched chambers at each end;
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    (b) backfill the excavation;


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    (c) demonstrate the pipe bursting procedure.


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    (d) on completion of the pipe installation flood the site to artificially bring the water table to
    m

    the ground surface and demonstrate that infiltration requirements of Part 4 of this
    Section are met.

    5 Should difficulties be encountered in completing the trial installation the Contractor shall
    modify his proposal for approval by the Engineer before recommencing work.

    6 Measures shall be taken to ensure that the replacement pipe does not become separated
    from the pipe expander should the system employ an insertion technique which allows the
    replacement pipe to slide within the pipe expander.

    11.8.5 Installation

    1 Shafts for launch and reception shall be existing manholes and excavations made over
    existing inspection chambers and service connections where the latter are proposed to be
    reconnected to the pipeline. Service connections to be abandoned or redirected to upstream
    or downstream chambers or manholes shall not be excavated.
    QCS 2014 Section 08: Drainage Works Page 28
    Part 11: Sewer Rehabilitation

    2 Unless specifically approved by the Engineer pipe bursting shall not be carried out by
    constructing shafts adjacent to manholes. Where necessary, the channel, benching and
    walls of existing manholes shall be altered to receive the pipe bursting equipment. All
    manhole alterations shall be made good.

    3 The Contractors attention is drawn to the potential problems arising from the inflow of
    groundwater and loss of ground from the outside of manholes. His proposed method of
    working shall take these into consideration and shall be subject to the Engineers approval
    and shall ensure that no inflow of groundwater or loss of ground occurs. Where manholes
    are located in roads, the Contractor shall obtain permission from the Roads Division prior to
    carrying out any wellpoint dewatering operations around the manhole. In the event that
    means of stabilising the ground around the manhole and connecting pipelines are not
    approved by the Engineer, the Contractor shall not use pipe bursting methods at that location
    unless any other alternative method is approved by the Engineer.

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    4 Existing service connections shall be disconnected from the existing pipeline in advance of

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    pipe bursting and reconnected on completion of the installation of the replacement pipe. In

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    the interval, the Contractor shall maintain service by temporarily connecting service
    connections to the sewerage system downstream of the section, by overpumping, or by such
    other method the Contractor may propose for the Engineers approval.

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    5 Sewer lengths to be rehabilitated shall be checked for the presence of collapses occurring
    subsequent to cleaning by gauging between shafts. Where a collapse is detected its position
    shall be determined and an additional shaft shall be excavated if the debris cannot be
    as

    removed.
    se

    6 Pipe bursting shall not commence unless sufficient lengths of replacement pipes are
    available on Site to complete the length of pipe to be rehabilitated.
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    7 Where pipe bursting is delayed for a period exceeding 7 days following cleaning, the pipeline
    ov

    shall be reinspected.

    8 Winching shall conform to the following requirements:


    it o

    (a) Details of the proposed winching method shall be submitted to the Engineer for
    et

    approval at least 7 days before the insertion date


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    (b) Winches shall be of the constant load type fitted with a direct reading load gauge. At
    the end of each days work, the Contractor shall provide the Engineer with a copy of
    the winching loads recorded at the start of any pull and during the pull at increments of
    20 m of winching distance and at any restart following temporary stops
    (c) Winches shall be fitted with an automatic device to disengage when the load
    exceeds a preset maximum load.
    (d) The Contractor shall supply sufficient cable in one continuous length to ensure the
    pull is continuous between approved winching points
    (e) Winches, cables and cable drums shall be provided with safety cages and supports
    (f) The Contractor shall provide a system of guide pulleys and bracings at each manhole
    (g) Nose cones fixed to the head of pipe expanders shall be fitted with a swivel attachment
    to prevent twist transmission between the winch cable and the nose cone
    QCS 2014 Section 08: Drainage Works Page 29
    Part 11: Sewer Rehabilitation

    (h) Where the Contractor proposes to use a lubricant to ease the pull, the type of
    lubricant, method of introduction, removal and quantity to be used shall be submitted
    for the Engineers approval before beginning winching
    (i) Trench sidewall support in the insertion trench shall remain completely separate from
    the pipe support system and shall be designed so as not to be in contact with the pipe
    or the winch cable.

    9 Replacement pipe shall be inserted in accordance with the following requirements:

    (a) the maximum force shall be within the stress limit of the pipe
    (b) continuous length pipelines shall not be used. The maximum pipe length for insertion
    shall be 1.5 m where pipe bursting is undertaken between excavated shafts and either
    700 mm or 800 mm where pipe bursting is undertaken from manhole to manhole
    (c) where a device is employed to exert force on the rear of the inserted pipe lengths, the

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    force applied to the inserted pipe shall be evenly distributed around the wall of the

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    pipe

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    (d) Where lengths of pipe are joined and a device is employed to exert force to the rear of
    the inserted pipe lengths, precautions shall be taken to ensure that no buckling,

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    crushing, twisting, or damage to the joint of the pipe takes place. Where, in the
    opinion of the Engineer, excessive deformation of the pipe has taken place, the pipe
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    shall be replaced at the Contractors expense.

    10 Where the lining is to be joined using Snap-Lock or similar fittings, the Contractor shall
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    comply with the manufacturers recommendations for jointing. Means of verifying the critical
    dimensions of the joints shall be provided on site by the Contractor. The joint shall be fitted
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    with a suitable sealing ring and shall be designed to be watertight against an excess external
    water pressure of 20 metres head.
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    11.9 INSPECTION AND TESTING OF PIPE LINES AFTER REHABILITATION


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    1 The completed sewer shall meet the leakage requirements of pressure tests or air tests as
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    specified in Part 4 of this Section.


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    et

    2 After completion of each length of sewer, the Contractor shall flush the pipeline and
    undertake a CCTV and deflection survey and provide video tapes, pictures on digital format
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    and site coding sheets to the Engineer.

    3 Where necessary the Contractor shall remove any debris and carry out any remedial work
    identified. Upon completion of remedial work and removal of debris the section shall be
    resurveyed and the Engineer provided with the latest CCTV video tapes. Further additional
    CCTV surveys resulting from the need to again clean or carry out further remedial work shall
    be at no additional cost to the Employer.

    4 The rehabilitated sewer shall be returned to service only after the written approval of the
    Engineer.

    5 During the guarantee period any defects which will affect the integrity or strength of the pipe
    shall be repaired at the Contractors expense, in a manner mutually agreed by the Engineer
    and the Contractor.
    QCS 2014 Section 08: Drainage Works Page 30
    Part 11: Sewer Rehabilitation

    11.10 MANHOLE REHABILITATION

    11.10.1 Scope

    1 The scope of work consists of the materials and types and methods of repair for the
    rehabilitation of manholes.

    11.10.2 General

    1 Manhole rehabilitation shall comprise but not be limited to any combination of the following:

    (a) Rehabilitation of walls or bases by plugging, patching, and removing, providing or


    replacing mortars, coatings, sealants and liners, to improve structural condition,
    prevent infiltration, provide corrosion protection or external tanking protection.

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    (b) Repair of shaft and cover slab and reconstruction to the required level

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    (c) Reinstallation or replacement of manhole frame and cover

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    (d) Installation of manhole sealing plate.

    11.10.3 Materials

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    1 Materials used shall be suitable proprietary materials for manhole rehabilitation and the
    specific application in which they are used. The materials shall be supplied in factory-labelled
    containers. All materials shall be mixed and applied in accordance with the manufacturers
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    instructions.
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    2 Materials used for plugging holes and stopping infiltration in manholes shall be either:

    (a) Premixed hydraulic cement consisting of Portland cement, graded silica aggregates,
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    special plasticising and accelerating agents with a set time of approximately 50 s and
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    a 10 min compressive strength of approximately 3.5 MPa and free of chlorides,


    gypsum, plasters, iron particles, or gas-forming agents
    (b) Siliconate-based liquid accelerator mixed with neat Portland cement with a set time of
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    approximately 50 s.
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    3 Materials used for patching, filling and repairing non-infiltration holes, cracks, and breaks in
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    concrete and masonry manholes shall comprise a premixed Portland cement-based


    hydraulic cement consisting of Portland cement, graded silica aggregates, special plasticising
    and accelerating agents with a set time of approximately 3 min or 15 min to suit application
    and a one-hour compressive strength of approximately 4.2 MPa. It shall not contain
    chlorides, gypsum, plasters, iron particles, or gas-forming agents.

    4 Materials used for waterproofing membrane, corrosion protection, and strengthening of


    concrete and block work manholes shall be:

    (a) liquid polymer modified water based waterproof coating which shall provide a secure
    mechanical and chemical bond with a curing time of approximately 1.5 h and a
    cured compressive strength of approximately 40 MPa. The coating shall be applied
    with a brush to surfaces without cracks or voids wider than 1.5 mm
    QCS 2014 Section 08: Drainage Works Page 31
    Part 11: Sewer Rehabilitation

    (b) 100 % solids, three-component system consisting of a two-component epoxy resin


    and a special blend of fillers which shall provide a secure mechanical and chemical
    bond with an initial curing time of approximately 4 h and a cured compressive
    strength of approximately 76 MPa. The resin with fillers shall be applied with a trowel
    to a thickness of 3 mm to 12 mm. Epoxy resin (without fillers) used for waterproofing
    and corrosion protection shall be applied with a brush.

    5 Remove all defective linings together with 100mm of adjoining good lining in existing
    manholes and other structures, including areas of lining covering leakage points.

    6 Break out defective concrete to sound concrete surface.

    7 Apply approved epoxy bonding agent and reinstate concrete using an approved concrete
    repair material.

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    11.10.4 Rehabilitation of Manhole Walls and Bases

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    1 Surfaces of manhole walls and bases shall be thoroughly cleaned to remove all loose

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    material and surface contaminants. Cleaning shall be accomplished by pressure jetting,
    sandblasting, or applying a 10 % solution of muriatic acid or hydrochloric acid. Where an acid
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    solution is used the surface shall be thoroughly rinsed and neutralised before the application
    of mortars and coatings.
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    2 After surface preparation and before the application of mortars and coatings, infiltration shall
    be stopped by sealing as specified in Clause 11.3.4.
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    11.10.5 Rehabilitation of Manhole Shafts and Slabs


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    1 The Contractor shall take all necessary precautions to prevent debris from damaging the
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    manholes and the sewer.


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    2 Shafts and cover slabs shall be repaired and rehabilitated with suitable sound materials
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    approved by the Engineer.


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    3 Rings shall be provided as appropriate to reconstruct the shaft to the required elevation.
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    11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or Replacement

    1 The Contractor shall remove covers, frames, and sealing plates. Where the Engineer
    determines that cover, frames and sealing plates are to be replaced, the Contractor shall
    dispose of them.

    2 The Contractor shall adjust the level and slope of the manhole cover as required. The
    manhole shall be raised by building precast concrete rings.

    3 Covers and frames determined by the Engineer to be in good condition shall be grit blasted
    and coated on all exposed faces with a zinc primer and coal-tar epoxy paint finish as
    specified for System C in Part 8 of this Section. Replacement covers, frames and sealing
    plates shall be as specified in Part 6 of this Section.
    QCS 2014 Section 08: Drainage Works Page 32
    Part 11: Sewer Rehabilitation

    4 The Contractor shall reinstall or replace the manhole cover and frame using either of the
    following methods in accordance with the Contract Drawings and clause 4.4 of this Section.

    5 Sealing plates shall be installed as specified in Part 6 of this Section.

    11.10.7 Inspection and Testing

    1 Completed rehabilitation works shall be visually inspected in the presence of the Engineer.
    Work that has become defective shall be redone at no additional cost to the Employer.

    11.11 MANHOLE LINING

    11.11.1 Scope

    1 The scope of work comprises structural rehabilitation of manholes by the installation of in-situ

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    glass fibre reinforced manhole liners.

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    11.11.2 Materials

    GRP liner materials shall be as specified in Part 7 of this Section.

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    11.11.3 Installation of Lining

    1 The cover slab and manhole cover shall be removed and disposed of off Site. The manhole
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    cover and frame shall be thoroughly cleaned, treated with two coats of bituminous paint and
    delivered to CED store and placed into storage.
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    2 Step irons shall be removed and the walls made good and prepared with 3:1 sand/cement
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    mortar.
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    3 Concrete surfaces to be lined shall be cleaned and lightly abraded prior to the application of
    the GRP. The GRP lining shall be built up by applying isophthalic or vinyl ester resin. A layer
    of ECR glass mat shall then be rolled into the resin using a suitable steel roller to exclude all
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    air and provide complete immersion of the glass fibre in the resin. After a period to allow pre-
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    gel to a tacky state, a second coat of resin shall be applied followed by a further layer of glass
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    fibre mat. This process shall be repeated until the total thickness of lining is approximately
    4 mm. Vinyl ester resin and C glass veil shall then be used to complete the lining.
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    4 Top surfaces of benching shall incorporate silica sand to form a non-slip surface.

    5 The precast cover slab shall be seated on the walls using sand/cement mortar. The joint shall
    be raked out 15 mm deep on the inside face and pointed with an approved pitch extended
    polyurethane sealant.

    6 GRP ladders of an approved pattern as specified may be purpose made to suit the depth of
    each manhole. Fixings for ladders shall be approved stainless steel stud anchors. Fixing
    holes shall be grouted with epoxy mortar and sealed as above. Rungs or treads shall be
    ribbed to provide a non-slip surface.
    QCS 2014 Section 08: Drainage Works Page 33
    Part 11: Sewer Rehabilitation

    11.11.4 Inspection and Testing

    1 After the manhole lining has been installed, the manhole shall be visually inspected in the
    presence of the Engineer and subject to the approval of the Engineer.

    2 Before the expiration of the Period of Maintenance, the Contractor shall visually inspect the
    lined manholes in the presence of the Employer or Engineer. Work that has become
    defective shall be redone at no additional cost to the Employer.

    END OF PART

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    QCS 2014 Section 08: Drainage Works Page 1
    Part 12: Vacuum Sewerage System

    12 VACUUM SEWERAGE SYSTEM .................................................................. 2

    12.1 GENERAL ...................................................................................................... 2


    12.1.1 Scope 2
    12.1.2 References 2
    12.1.3 Definitions 2
    12.1.4 System Description 3
    12.1.5 Submittals 3
    12.1.6 Quality Assurance 4
    12.1.7 Warranty 4
    12.1.8 System Operation 4
    12.1.9 Commissioning 5
    12.1.10 Maintenance 5

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    12.2 SYSTEM DESIGN AND PERFORMANCE .................................................... 5

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    12.2.1 General 5
    12.2.2 Design of the System 5
    12.2.3 Design of Vacuum Station 6
    12.2.4 Design of Collection Chambers
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    12.2.5 Design of Vacuum Pipelines 7
    12.3 PRINCIPAL SYSTEM COMPONENTS ......................................................... 8
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    12.3.1 General 8
    12.3.2 Vacuum Pipelines 8
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    12.3.3 Collection Chamber 9


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


    12.3.8 Vacuum Pumps 11
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    12.3.9 Forwarding Sewage Pumps 11


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    12.3.10 Motor Control Centre 11


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    12.3.11 Telemetry Outstation 12


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


    12.4.1 Pipelines 12
    12.4.2 Pipe Joints for Vacuum Pipelines 12
    12.4.3 Pumps, Motors and Instrumentation 13
    12.5 TESTING ..................................................................................................... 13
    12.5.1 General 13
    12.5.2 Testing of Interface Valves, Controllers and Sensors 13
    12.5.3 Testing of Pipelines 13
    12.5.4 Testing of Pumps, Motors and Instrumentation 14
    12.6 TRAINING OF EMPLOYERS PERSONNEL............................................... 14
    QCS 2014 Section 08: Drainage Works Page 2
    Part 12: Vacuum Sewerage System

    12 VACUUM SEWERAGE SYSTEM


    12.1 GENERAL

    12.1.1 Scope

    1 This Part includes the specifications for the design and provision of vacuum sewerage
    systems.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1 General

    .
    Part 2 Earthworks

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    Part 3 Pipes and Fittings Materials
    Part 4 Pipe Installation

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    Part 5 Valves, Penstocks and Appurtenances
    Part 6 Miscellaneous Metalwork
    Part 8 Protective Coatings and Painting
    Section 1, General ta
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    Section 9, Mechanical and Electrical Equipment
    Section 10, Instrumentation, Control and Automation
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    Section 21, Electrical Works


    Section 22, Air Conditioning, Refrigeration and Ventilation.
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    12.1.2 References
    BS 5500, welded pressure vessels
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    European Standard CEN/TC 165, Vacuum sewerage system outside buildings.


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


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    et

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


    (b) Collection Chamber: interface between the vacuum sewerage system and the
    collection sewers consisting of a collection sump and interface valve pit.
    (c) Collection Sump: storage capacity provided to store flows of sewage until sufficient
    volume has accumulated to activate the interface valve. Storage may also be provided
    to reduce the risk of flooding if there is a system failure.
    (d) Controller: device which, when activated by the sensor, opens the interface valve and,
    after the passage of sewage and air, closes the valve.
    (e) Forwarding Pumps: pumps installed at the vacuum station to pump the sewage from
    the vacuum system to the trunk sewer.
    (f) Interface Valve: valve which admits the flow of sewage and air into the vacuum sewer
    through the service connection.
    QCS 2014 Section 08: Drainage Works Page 3
    Part 12: Vacuum Sewerage System

    (g) Isolation Valve: valve installed to isolate a particular section in the vacuum sewer
    network.
    (h) Lift: up-grade section between two down-grade sections of a vacuum pipeline. The lift
    height is the difference in sewer invert levels between two successive down-grade
    sections. The static lift is the increase in the hydraulic grade line at a lift and is
    generally the increase in invert level minus the internal diameter.
    (i) Sensor: device which senses the presence of sewage in the collection sump and
    activates the controller to open the interface valve.
    (j) Service Connection: that part of the vacuum pipeline which connects a single collection
    chamber to the vacuum sewer.
    (k) Vacuum Generator: equipment installed at the vacuum station to generate a vacuum.
    (l) Vacuum Pipeline: pipeline under negative pressure.

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    (m) Vacuum Pump: pump that creates the vacuum in the vacuum pipeline.

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    (n) Vacuum Recovery Time: time taken after the operation of an interface valve for the

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    negative pressure at the valve to be restored to its original value.
    (o) Vacuum Sewer: the major part of the vacuum pipeline into which the service
    connections discharge.
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    (p) Vacuum Station: vacuum generators, vacuum vessel (or sewage sump), forwarding
    pumps and system controls.
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    (q) Vacuum Vessel: negative pressure vessel connected to the vacuum pump. The
    vacuum sewer discharges into the vacuum vessel and the forwarding pumps pump
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    sewage from the vessel. The vacuum pumps maintain a negative pressure in the
    vessel. When the vacuum generator is an ejector pump, the vacuum vessel is
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    replaced by a sewage sump at atmospheric pressure.


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    12.1.4 System Description

    1 The Contractor shall be solely responsible for the design and construction of the system to
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    meet the specified requirements.


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

    4 The maximum noise level at the vacuum station and elsewhere in the system shall not
    exceed 65 dbA.

    12.1.5 Submittals

    1 The Contractor shall submit complete data and details of vacuum sewerage systems for the
    Engineers approval as follows:

    (a) method statement which shall include :


    (i) name and experience of specialist
    (ii) detailed procedure for the works
    QCS 2014 Section 08: Drainage Works Page 4
    Part 12: Vacuum Sewerage System

    (iii) list of all construction plant and tools


    (iv) safety procedures
    (b) hydraulic, structural, mechanical and electrical calculations used in the preparation of
    the shop drawings.
    (c) shop drawings for all components and the complete system.
    (d) certificates that all components and equipment to be provided are suitable and made
    of such materials to withstand the prevailing climatic conditions of Qatar and the
    corrosive environment. Details of proposed corrosion protection systems shall be
    provided.
    (e) complete justification for any proposed changes in materials.
    (f) Training program

    .
    (g) operation and maintenance methods manual which shall include:

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    (i) complete information of the system illustrated in detailed drawings

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    (ii) detailed procedures for correct operation and maintenance of all system
    components.
    (iii) reprogramming manual
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    2 The Contractor shall not procure materials or commence installation of the Works until the
    Engineer has approved his submittals.
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    12.1.6 Quality Assurance


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    1 The vacuum system shall be provided by approved, specialist manufacturers, suppliers and
    installers designated in the contract Project Specification.
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    2 All supervisors and technicians employed shall be fully competent in the installation methods.
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    12.1.7 Warranty
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    1 The control equipment shall be provided with a satisfactory performance warranty.


    et

    2 In addition to the warranty requirements of Part 1 of this Section, the vacuum sewerage
    m

    system supplier shall warrant that the system and its components will meet the performance
    for a period of 24 months from the date of startup. The vacuum system supplier shall be
    solely responsible for the warranty. The warranty shall be in the form of a letter and report
    which shall be submitted to the Engineer, for review. Within the warranty period, any
    remedies necessary to bring the vacuum sewerage system into compliance with the
    specifications shall be the sole responsibility of the vacuum system supplier.

    3 The Contractor shall furnish the Employer with manufacturers warranty and guarantee
    certificates for all equipment.

    12.1.8 System Operation

    1 On satisfactory completion, the Contractor shall operate and run the vacuum system for a
    period of 400 days during which time he shall be totally responsible for all maintenance
    including spares.
    QCS 2014 Section 08: Drainage Works Page 5
    Part 12: Vacuum Sewerage System

    12.1.9 Commissioning

    1 The Contractor shall submit instruction manuals in draft to the Engineer four weeks prior to
    the commissioning.

    2 The Contractor shall demonstrate to the Engineer that all equipment functions to meet the
    design criteria and specifications.

    12.1.10 Maintenance

    1 The Contractor shall provide any special tools and equipment needed to operate and
    maintain the system and provide spare parts for two years operation and an additional 400
    days for the maintenance, all at his expense.

    12.2 SYSTEM DESIGN AND PERFORMANCE

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    12.2.1 General

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    1 The vacuum system shall be supplied by a manufacturer approved by the Engineer.

    2
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    The general location of the vacuum sewerage system including the locations of collection
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    chambers, vacuum pipelines, vacuum station and pressure pipeline discharging to the trunk
    sewer which forms part of the gravity sewerage system shall be as shown on the Drawings.
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    3 The Contractor shall be responsible for carrying out any additional site investigations, for the
    design, and for provision of a complete system including supply of all materials and
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    equipment, testing, startup and commissioning.


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    12.2.2 Design of the System


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    1 The design of the system shall satisfy either of the two conditions:

    (a) outline design of the sewerage system provided by the Engineer


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    (b) as an alternative option proposed by the Contractor to avoid deep sewers in the
    it

    Contract in which case the design will be based on the Contract Drawings
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    2 The Contractor shall not procure materials, equipment or begin construction of the Works
    m

    until the Engineer has approved the design and all other submittals.

    3 The vacuum sewerage system shall intercept sewage flow and convey the flow to collection
    chambers. Collection chambers, interface valves and vacuum pipelines shall be located so
    that they do not interfere with or obstruct existing services and access thereto.

    4 Sewage from the collection chambers shall be drawn into the system through interface valves
    and conveyed by the vacuum pipelines to a collection vessel located in the vacuum station,
    equipped with vacuum pumps.

    5 Sewage from the vacuum station shall be pumped through the pressure pipeline to the
    gravity sewerage system. All necessary pipework shall be included from the vacuum station
    to the point of discharge to the gravity sewer.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 12: Vacuum Sewerage System

    12.2.3 Design of Vacuum Station

    1 The Contractors design shall optimise the number and locations of the vacuum stations.
    Where more than one station is required, the size of the collection vessels, vacuum pumps
    and other equipment shall be standardised as far as practicable.

    2 Vacuum stations shall comprise all civil works; mechanical and electrical works including
    pipework, vacuum vessel, vacuum pumps, cooling systems, forwarding pumps, odour control
    equipment; motor control centre; instrumentation including vacuum data loggers, and valve
    telemetry display and telemetry outstation and connection to the control centre; lighting and
    all other work necessary in accordance with Sections 9 and 21 to make the vacuum station
    complete in all respects.

    3 Forwarding pumps shall be controlled by level probes installed in the collection vessel; two
    sets of probes shall be installed, an upper set to run on normal day operation and a lower set

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    to empty the vessel under extreme low flow conditions. The pump control station shall include

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    automatic timer, indication and alarm in accordance with Sections 9 and 21.

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    4 The vacuum station shall be of cavity wall construction. The Contractor shall design the
    station building and submit detailed design drawings for the Engineers approval. The station

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    building shall incorporate the following minimum requirements:
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    2
    (a) minimum internal floor area 12 m
    (b) external cement, sand or concrete blocks
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    (c) aluminium doors and window frames


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


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    (f) QGEWC supply meters to be mounted in external box (QGEWC supply)


    (g) a connection point to the incoming vacuum sewer, fitted with an isolation valve, for
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    independently testing vacuum valves


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    (h) a separate room housing a single water closet and hand basin with both hot and cold
    et

    running water
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    (i) water supply to a 200 l GRP header tank above the roof
    (j) external washdown tap with concreted splash area below, draining to the on-site
    vacuum collection chamber
    (k) activated carbon type exhaust air filter
    (l) a collection chamber shall be constructed at the site which shall receive the flows
    from the water closet, hand basin, external washdown tap, and coolant water from
    the liquid ring vacuum pumps.

    5 The vacuum station shall include all pipework necessary for satisfactory performance,
    operation and maintenance.
    QCS 2014 Section 08: Drainage Works Page 7
    Part 12: Vacuum Sewerage System

    12.2.4 Design of Collection Chambers

    1 Collection chambers shall be designed such that in each case the lowest invert of the
    incoming gravity sewer is above the high operation sewerage level of the interface valve to
    avoid surcharging the gravity sewers during normal operation.

    2 Collection chamber sumps shall be sized to give a 4 h retention capacity at average flow
    below the level of the incoming sewers. The Contractor shall account for the probability of
    power failure and its consequences. Provision shall be made in the control panel and cabling
    for connecting mobile standby power generation.

    3 Collection chambers shall be fitted with a level sensing devices and local and remote alarms
    as designated, and shall be so located and fitted with access openings to enable clearing of
    sewage using pumping or vacuum tankers. In no case will the provision of facilities for
    discharge of sewage to the surface water drains be permitted.

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    4 Collection chambers shall incorporate an intermediate platform within the chamber to

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    facilitate easy access to the vacuum interface valve. The area of the platform must be at
    least equal to half the plan area of the chamber. Access to the lower part of the chamber
    below the intermediate platform shall be provided with a minimum 600 mm diameter clear

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    opening. Where the intermediate platform is provided by means of a concrete slab, the
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    access hole into the lower chamber shall be provided with a galvanised open mesh cover as
    specified in Clause 6.5.7 of this Section permitting viewing of the lower part of the chamber
    from the top of the chamber.
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    5 Vacuum interface valves in collection chambers shall incorporate an auxiliary suction pipe
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    such that if the valve fails the chamber can be emptied into the vacuum pipeline. The
    auxiliary suction pipe shall be positioned within 100 mm below the cover level and shall be
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    operable from ground level outside the chamber.


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    6 Interface valve assemblies shall incorporate isolating valves such that the interface valves
    can be easily removed without necessitating loss of vacuum in the vacuum pipeline.
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    7 Where breathers are used on vacuum interface valves they shall not exceed 5 m in length.
    it

    Where the breather head is not against a structure to which it can be securely fixed the
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    breather head shall be protected by a 50 mm by 50 mm galvanised steel angle cast in


    concrete, the head being fixed into the angle with plastic cable ties or similar. Where any
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    double valve collection chambers are used each valve shall have a dedicated breather.

    8 The sump shall be vented to allow the intake of air. The sump may be vented by the gravity
    system provided that the operation of the vacuum system does not unseal the traps on the
    internal sewerage system and that the internal sewerage system is vented to atmosphere.

    12.2.5 Design of Vacuum Pipelines

    1 Pipeline profiles shall be as follows:

    (a) the size of individual lifts shall be kept as small as possible to maximise vacuum
    transport efficiency and many small lifts shall be provided instead of one large lift.
    The minimum horizontal distances between profile changes shall be 6 m for vacuum
    sewers and 1.5 m for service connections
    QCS 2014 Section 08: Drainage Works Page 8
    Part 12: Vacuum Sewerage System

    (b) except at lifts, vacuum sewers shall have a minimum gradient of 1:500 in the
    direction of flow. Profile changes shall be made where necessary to ensure that the
    pipeline depth does not become excessive
    (c) where the ground surface has a gradient of 1:500 or more in the direction of flow,
    vacuum sewers may be laid parallel to the surface. Stagnation of sewage shall be
    avoided at locations followed by an uphill section
    (d) lifts shall generally not be more than 1.5 m, but where conditions are such that a lift
    exceeds 1.5 m special care shall be taken in the design of pipelines by taking into
    consideration the flow capacity and total lengths of the vacuum pipeline.

    2 Air Flow. The total average air/liquid ratio shall not be less than 1.5:1. The Contractor shall
    identify in his calculations the average air liquid flows for which the system is designed.

    3 Minimum Negative Pressure. The system design shall achieve a minimum negative pressure

    l .
    of 25 kPa (gauge) under no flow conditions at each interface valve.

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    rw
    4 Vacuum Recovery. The system shall be designed so that the vacuum recovery will be fast
    enough to ensure that temporary surcharging of collection chambers does not occur under
    normal flow conditions.

    5 ta
    Length of Vacuum Sewers. Lengths of vacuum sewers shall be such to enable the system to
    qa
    restart automatically and recover vacuum following rectification any breakdown.

    6 Service Connections. Service connections shall slope away from the interface valve and
    as

    shall connect into the top sector of the vacuum sewer contained within the angle of +60
    about the vertical axis.
    se

    7 Branch Connections. Branch connections to vacuum sewers shall be by junctions connected


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    to the sewer above the horizontal axis, and the angle of the junction shall ensure that the flow
    ov

    towards the vacuum station is generated and backflow is minimised. No connection shall be
    made within 2 m of a lift.
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    8 Isolating Measures. Adequate means of isolating lengths of vacuum sewer to permit


    it

    maintenance shall be provided by isolating valves or appropriate inspecting pipes. Isolating


    et

    valves shall be suitable for service under vacuum and pressure and shall be capable of
    sustaining a differential vacuum of 80 kPa.. Buried valves shall be provided with extension
    m

    spindles and surface boxes.

    12.3 PRINCIPAL SYSTEM COMPONENTS

    12.3.1 General

    1 All materials used in the manufacture of collection chamber, interface valve and controller
    shall be capable of resisting corrosion from soils, groundwater, sewage and sewage gases.

    12.3.2 Vacuum Pipelines

    1 Vacuum sewers shall have a minimum diameter of 80 mm and service connections shall
    have a minimum diameter of 50 mm.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 12: Vacuum Sewerage System

    2 All vacuum pipes and fittings shall be of MDPE as specified in Part 3 of this Section. The
    minimum pressure rating for plastic pipes shall be 0.6 MPa but higher ratings shall be
    employed if the pipe has an initial ovality or if progressive deformation is likely to occur.

    3 Pipelines and components shall be designed to withstand the stresses arising from earth
    cover, traffic and cyclic loads, particularly at connections to structures and the range of
    negative pressures arising during operation and testing.

    12.3.3 Collection Chamber

    1 The chamber shall be watertight and shall be protected against floatation in waterlogged
    areas. The internal surface of the sump shall be smooth and the sump shall be designed to
    be self-cleansing.

    2 Access to the chamber shall be through a manhole cover and frame as specified in Part 4 of

    l .
    this section. The size of chamber shall be similar to inspection chamber on the Contract

    .l.
    Drawing.

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    12.3.4 Interface valves

    1
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    Interface valves shall be all ABS construction and shall be capable of performing sufficient
    cycles to evacuate 3000 m3 without attention. All materials shall be serviceable at 50 C
    qa
    ambient temperature and 100 % humidity conditions except if the valves are exposed to the
    sun where the temperature could reach 80oC. The valve mechanism shall be explosion
    as

    proof.
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    2 Interface valves shall:

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


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


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    et

    (e) fail safe in the closed position


    m

    (f) prevent backflow to the collection sump


    (g) evacuate the batch volume on each cycle.

    3 Batteries shall not be used in valve actuating or control elements.

    4 Valve opening initiation level and valve opening times shall both be adjustable.

    5 Configurations shall be such that the vacuum ensures positive valve seating.

    6 When the valve is open, the flow stream shall not be obstructed by the valve plunger. The
    valve may be protected from obstruction by the installation of constriction in the suction lift
    pipework.

    7 The internal diameter of the suction pipe shall not be greater than the internal diameter of the
    interface valve which shall not be greater than the internal diameter of the service
    connection.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 12: Vacuum Sewerage System

    8 Valves installed in sumps shall be capable of operating when submerged in sewage.

    9 Valves shall be designed to allow easy access for maintenance. Fixing arrangements shall
    enable the valve and control system to be readily replaced.

    12.3.5 Controller

    1 Controllers shall

    (a) be explosion proof


    (b) open the interface valve only if there is a minimum vacuum of 15 kPa available
    (c) maintain the valve fully open until the sump has been fully emptied
    (d) be adjustable so that a range of air to sewage volume ratios can be obtained.

    l .
    .l.
    2 If the introduction of air is allowed after the sewage has been fully emptied, the controller

    rw
    shall maintain the valve in the open position for a further period.

    12.3.6 Sensor
    ta
    qa
    1 The interface valve shall be provided with a sensor to determine the level of sewage in the
    collection sump. The sensor shall be designed to be fouling resistant. Where level sensor
    pipes are employed they shall not be less than 45 mm diameter.
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    12.3.7 Vacuum Vessel


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    1 Flows from vacuum pipelines discharged to vacuum stations shall be collected in a vacuum
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    vessel. The vessel shall be manufactured of steel and be in accordance with the
    requirements of BS 5500 or other corrosion resistant material such as GRP. The steel shall
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    be corrosion protected in accordance with Clause 8.4.2 of this Section.

    2 Vessel capacity shall suit vacuum generator and forwarding pump capacities and the vacuum
    o

    rate of inflow and storage volume.


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    et

    3 Vessels shall
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    (a) be fabricated and tested for a working vacuum of 70 kPa and rest vacuum of 90 kPa
    (b) be fitted with the required number of correctly sized sewage inlet and outlet
    pipes which shall be integral with the vessel. No inlet pipes shall be connected
    below the system emergency stop level. The inlet and outlet pipes shall be
    located such that solids do not accumulate in the vessel
    (c) be provided with a suitable flanged manhole access cover to permit entry for internal
    inspection and maintenance
    (d) be fitted with a level control system which is suitable for operation in vacuum and
    easily removed for adjustment or replacement
    (e) be fitted with suitable galvanised mild steel cradles for bolting to the concrete floor
    of vacuum station.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 12: Vacuum Sewerage System

    4 The pump manufacturers advice on the need to install equalising lines connecting the
    discharge side of the pumps to the vacuum vessel shall be sought. If required by the pump
    manufacturer, a suitably sized and valved equalising line from each pump to the vessel shall
    be provided

    5 The steel vessel shall be internally and externally protected from corrosion with a suitable
    protection system in accordance with Part 8 of this Section. Details of the proposed
    protection method shall be submitted as required by Clause 12.1.5 of this Section. The
    protection system shall take account of accessibility for inspection and maintenance.

    12.3.8 Vacuum Pumps

    1 Two vacuum generators such as liquid ring or rotary vane pumps or ejector pumps shall be
    provided each having sufficient capacity to serve the system.

    l .
    2 Vacuum pumps shall be capable of continuous operation and shall be designed for a

    .l.
    minimum of 12 starts per hour. Pumps of equal capacity shall be installed such that one

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    pump can act as standby.

    3 Vacuum pumps shall be operated by pressure switches attached to the vacuum vessel. The

    ta
    pumps shall operate on the liquid ring principle and shall exhaust air from the vacuum vessel.
    One duty and one standby vacuum pump shall operate in conjunction with a common tank
    qa
    containing the operating liquid, normally water, and associated pipework connecting the
    pumps to the tank so that the water level is maintained at all times. The service liquid shall be
    as

    maintained at 30 C by a refrigerated cooling unit, circulating the liquid through the tank.
    Ambient air temperatures up to 50 C shall not limit the functioning of this equipment or
    se

    cause the vacuum pumps to trip on high circulating water temperature.


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    4 Each pump shall be provided with a rotary seal comprising a rubber seal, spring loaded and
    rotating against a carbon face. Suitable non-return valves shall be provided to prevent the
    ov

    exhausted air from returning into the vacuum system. The pressure switches shall control
    the operation of the vacuum pumps to maintain the vacuum within the system.
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    12.3.9 Forwarding Sewage Pumps


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    et

    1 Forwarding pumps or pressure vessels used to forward the sewage shall have sufficient
    m

    capacity to serve the system. Forwarding pumps shall be as specified in Section 9 except as
    modified below.

    2 Forwarding pumps shall be unchokeable sewage pumps suitable for operating under
    negative pressure without cavitations. They shall be suitable for a maximum of 12 starts per
    hour. The motor speed shall be 1500 rpm.

    3 A 25 mm connection of swept flanged tee shall be provided on each pump delivery, with
    hand hole incorporated in the impeller casing or duckfoot bend under the pump and
    reversible wear plate fitted under the impeller. Pumps shall be fitted with lip seals to prevent
    loss of vacuum from the shaft when pumping from the sewage vessel.

    12.3.10 Motor Control Centre

    1 The motor control centre for the operation of all pumps shall be as specified in Sections 9
    and 21.
    QCS 2014 Section 08: Drainage Works Page 12
    Part 12: Vacuum Sewerage System

    2 The operation of pumps shall be controlled by a programmable logic controller and shall
    prevent simultaneous starting of the vacuum and sewage pumps to prevent surges.

    3 The controls shall permit the manual or programmed selection of duty and standby pumps
    and shall provide for automatic start of the standby pumps in the event of duty pump failure.

    4 The vacuum pumps shall be controlled by monitoring the vacuum in the vacuum vessel with
    adjustable pressure switches set to the desired operating range. Additional pressure devices
    shall be provided to indicate and record both high and low vacuum.

    5 The level control system shall respond to the following sewage levels in the vacuum vessel or
    the sewage sump:
    Emergency stop level (High Level) - stops vacuum generation
    - forwarding pumps operate

    .
    Start level - starts forwarding pumps

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    .l.
    Normal stop level (Low Level) - stops forwarding pumps.

    rw
    6 All power, control and instrumentation cabling shall be provided as required for the complete
    system.

    7 ta
    The following alarms with appropriate remote signalling shall be provided:
    qa
    (a) low vacuum alarm indicating that system vacuum is below the minimum preset level
    as

    (b) high sewage alarm indicating that sewage level in the vacuum vessel or sewage sump
    is at the high level mark.
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    12.3.11 Telemetry Outstation


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


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    12.3.12 Discharge Pipelines


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    1 All pipes, fittings and valves on the discharge side of the forwarding pumps shall be as
    it

    specified in Parts 3 and 5 of this Section.


    et

    12.4 INSTALLATION OF THE SYSTEM


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    12.4.1 Pipelines

    1 Vacuum and pressure pipelines shall be installed in accordance with Part 4 of this section
    and valves shall be installed as specified in Part 5 of this Section, except where modified
    herein.

    2 Vacuum pipelines shall be jointed as specified herein.

    12.4.2 Pipe Joints for Vacuum Pipelines

    1 Pipeline components shall be connected in such a way that the pipeline is sealed and
    accommodates static and dynamic stresses.

    2 Where mechanical joints are employed they shall comply with the requirements of Part 3 of
    this Section and be suitable for vacuum service.
    QCS 2014 Section 08: Drainage Works Page 13
    Part 12: Vacuum Sewerage System

    3 Pipelines shall be securely anchored or bedded to resist thrust arising from internal vacuum.
    Precautions shall be taken against flotation where necessary.

    4 Welded joints shall only be made by suitably trained personnel using approved welding
    equipment.

    12.4.3 Pumps, Motors and Instrumentation

    1 Pumps shall be installed as specified in Section 9.

    2 Motors shall be installed as specified in Sections 9 and 21.

    3 Instrumentation shall be installed as specified in Section 10.

    12.5 TESTING

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    .l.
    12.5.1 General

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    1 The Contractor shall prepare and submit his proposed testing program for the approval of the
    Engineer.

    2 ta
    The Engineer shall be notified 24 hours in advance of testing.
    qa
    3 Pipelines and equipment shall be adequately restrained before testing.
    as

    4 On satisfactory completion of testing, the Contractor shall submit a report describing the tests
    se

    undertaken and the test results.

    12.5.2 Testing of Interface Valves, Controllers and Sensors


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    1 Interface valves, controllers and sensors shall be tested to demonstrate that they function
    correctly to meet specified duties.
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    2 Where new valves or controllers are introduced or significant changes are made to proven
    it

    valves, laboratory tests shall be undertaken under simulated working conditions and test
    et

    certificates provided. The tests, using water and air, shall demonstrate that the complete
    valve mechanism can comply with the preceding performance requirements.
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    12.5.3 Testing of Pipelines

    1 Pipelines shall be pressure and vacuum tested.

    2 Pressure tests shall be carried out in accordance with Clause 4.5.3 of this Section.

    3 Before carrying out a vacuum test, the Contractor shall ensure that the test equipment is
    calibrated, is in working order and correctly fitted to the pipe.

    4 The permitted loss of vacuum in pipeline tests shall be corrected to allow for changes in
    temperature and atmospheric pressure. Pipe temperatures atmospheric pressure shall be
    recorded at the start of the test and at hourly intervals.
    QCS 2014 Section 08: Drainage Works Page 14
    Part 12: Vacuum Sewerage System

    5 Regular vacuum testing and final vacuum testing shall be carried out as specified herein. In
    the event of failure under either test, the leaks shall be located and repaired, and the tests
    redone.

    6 Regular vacuum testing of all service connections and vacuum sewers shall be carried out on
    the pipelines before backfilling and in sections as approved by the Engineer. The test
    duration shall be 1 h. Open ends of pipeline shall be capped and a vacuum of 80 kPa applied
    and allowed to stabilise for 15 min after which time the fall in vacuum shall not exceed 1.0 %
    over the 1 h test.

    7 Final testing of service connections, vacuum sewers and vacuum vessels shall be tested
    before the installation of the interface valves. The test duration shall be 4 h. A vacuum of
    80 kPa shall be applied using the vacuum pumps in the vacuum station. Instrumentation shall
    be provided to record system vacuum during testing. After the vacuum has stabilised, the fall
    in vacuum shall not exceed 1.0 %/h for each hour of the test.

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    .l.
    12.5.4 Testing of Pumps, Motors and Instrumentation

    rw
    1 Testing of pumps shall be in accordance with Section 9.

    2
    ta
    Testing of motors shall be in accordance with Sections 9 and 21.
    qa
    3 Testing of instrumentation shall be in accordance with Section 10.
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    12.6 TRAINING OF EMPLOYERS PERSONNEL


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    1 The Contractor shall prepare and submit a training program and manual for the approval of
    the Engineer. The training shall cover system installation, operation and maintenance, and
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    record keeping and interpretation.


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    2 On-site training shall be provided by the system manufacturer specialist staff for a minimum
    period of 90 days.
    o

    3 The Contractor shall provide facilities required for implementation of the training program.
    it
    et

    END OF PART
    m
    QCS 2014 Section 08: Drainage Works Page 1
    Part 02: Earthworks

    2 EARTHWORKS ............................................................................................. 2

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


    2.1.1 Scope 2
    2.1.2 References 2
    2.1.3 Definitions 2
    2.1.4 Trial Holes 3
    2.1.5 Services Co-ordination 3
    2.2 EXCAVATIONS ............................................................................................. 3
    2.2.1 General 3
    2.2.2 Surfaces 3
    2.2.3 Materials 4

    .
    2.2.4 Excavations to be Kept Dry 5

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    .l.
    2.2.5 Access 5

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    2.2.6 Trench Excavations 6
    2.2.7 Appurtenant Structures for Pipelines 8
    2.2.8 Excavation in Roads 9
    2.2.9 Excavation in Areas Other Than Road Reserves
    ta 9
    qa
    2.2.10 Support of Excavations 10
    2.2.11 Slips and Falls and Excess Excavation 10
    2.2.12 Trimming and Levelling 11
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    2.2.13 Excavations Not to be Left Open 11


    2.2.14 Dewatering of Excavations 12
    se

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


    er

    2.3.1 Pipe Bedding 14


    2.3.2 Pipe Surround 16
    ov

    2.3.3 Geotextile Filter Membrane 16


    2.3.4 Backfilling Excavation 17
    o

    2.3.5 Backfilling Excavations with Cement-Bound Granular Material 19


    it

    2.3.6 Backfilling Excavation with Flowable Fill (Foamed Concrete) 21


    et

    2.3.7 Backfilling Next to Pipeline Structures 22


    2.3.8 No-Fines Concrete as Trench Backfill 22
    m

    2.4 REINSTATEMENT OF SURFACES ............................................................ 22


    2.4.1 Reinstatement within the Highway 22
    2.4.2 Reinstatement of Surfaces Other Than in the Highway 22
    2.5 EXISTING SERVICES ................................................................................. 23

    2.6 BLASTING ................................................................................................... 24

    2.7 MISCELLANEOUS ...................................................................................... 26


    2.7.1 Service Ducts 26
    2.7.2 Formation of Bunds and Embankments 26
    QCS 2014 Section 08: Drainage Works Page 2
    Part 02: Earthworks

    2 EARTHWORKS
    2.1 GENERAL

    2.1.1 Scope

    1 This Part includes earthworks for pipelines including, excavation, granular pipe bedding,
    concrete protection of pipe, backfill and compaction, and service protection ducts to protect
    existing utilities.

    2 Related Sections are as follows:


    This Section
    Part 1, General

    .
    Part 3, Pipeline Installation

    l
    .l.
    Part 9, Trenchless Pipeline Construction
    Part 10, Sewer Rehabilitation

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    Part 12, Vacuum Sewerage System
    Section 1, General
    Section 3,
    Section 5,
    Ground Investigation
    Concrete ta
    qa
    Section 6, Roadworks
    Section 12, Earthworks Related to Buildings
    Section 28, Landscaping.
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    2.1.2 References
    er

    1 The following standards and other documents are referred to in this Part
    BS 410........................Test sieves
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    BS 1924......................Stabilised materials for civil engineering purposes


    BS 6031......................Code of practice for earthworks
    o

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


    it
    et

    BS EN ISO 10319 ......Geosynthetics


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


    BS EN ISO 12956 ......Geotextiles and geotextile-related products

    Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance


    Section, Code of Practice and Specification for Road Openings in the Highway

    2.1.3 Definitions

    1 Trench excavation means excavation in all materials of whatever nature encountered for
    trenches into which pipes, ducts or cables are to be laid, or manholes, chambers and
    appurtenances constructed, and the term pipe shall mean pipe of all kinds and for whatever
    purposes.
    QCS 2014 Section 08: Drainage Works Page 3
    Part 02: Earthworks

    2.1.4 Trial Holes

    1 Trial holes for determining the location of existing services shall be excavated well ahead of
    the trench excavation to such depths as necessary to determine and confirm the alignment
    for the trench and the soil condition. The Contractor shall arrange for the refilling and
    reinstatement of trial holes to be carried out immediately after the required information is
    obtained. The reinstatement of trial holes shall be carried out to the approval of the Engineer.

    2.1.5 Services Co-ordination

    1 In addition to the requirements of the relevant Parts of Section 1 and Part 1 of this Section,
    the following paragraphs shall apply to services co-ordination for pipeline excavations.

    2 Notwithstanding any relevant information furnished by the Engineer, the Contractor shall be
    responsible for ascertaining from his own inspection of the Site and the respective Utilities

    l .
    Service Departments and private landowners the position of all mains, pipes, cables, and

    .l.
    other services and facilities whether underground or overhead within or near the Site.

    rw
    3 Except as otherwise specified, the Contractor shall make arrangements necessary for
    carrying out the Works with the various Utilities Service Departments and private landowners.

    ta
    The Contractor shall be responsible for any damage caused as a result of his omission in this
    respect, and for any damage caused by his failure to notify the Engineers representative and
    qa
    the agencies concerned immediately any service is encountered in the excavations.
    as

    4 Work on existing services is specified in Subparts 2.4, 2.5 and 2.7 of this Part.
    se

    2.2 EXCAVATIONS
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    2.2.1 General
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    1 The Contractor shall be deemed to have obtained additional site information in accordance
    with Clause 1.3.1 of this Section.
    o

    2.2.2 Surfaces
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    et

    1 Before the surface of the area to be excavated is disturbed the Contractor shall take and
    m

    record levels of the area in the presence of the Engineer. At least two days notice shall be
    provided to the Engineer.

    2 The demolition of existing works shall be in accordance with Section 2.

    3 Except as otherwise designated in the Project Specification or directed by the Engineer,


    breaking out and restoration of existing surfaces and works shall be done in accordance with
    the Code of Practice and Specification for Road Openings in the Highway published by the
    Highway Maintenance Section, Civil Engineering Department, Ministry of Municipal Affairs
    and Agriculture.

    4 Surface materials shall be carefully stripped or otherwise removed and set aside for reuse,
    restoration, or replacement as directed by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 4
    Part 02: Earthworks

    5 Where the trench excavation crosses surface barriers such as fences and walls the
    Contractor shall

    (a) obtain the written approval of the Engineer before breaching the barrier
    (b) minimise the size of the opening, where possible using a short heading
    (c) carefully dismantle the barrier as necessary for reuse, replacement, or reinstatement
    (d) provide temporary fencing for any removed parts of such barriers as directed by the
    Engineer.

    2.2.3 Materials

    1 Selected excavated material shall be the most suitable portions of the excavated material
    free from matter harmful to other materials in the works and which is capable of being
    compacted to the specified density to form stable fill. The material shall also conform to the

    l .
    requirements mentioned in Clauses 3.3.2, 3.3.3 and 3.3.5 of Section 6.

    .l.
    rw
    2 It shall be the responsibility of the Contractor to locate suitable borrowed or imported fill
    material which may be necessary and to carry out such tests as the Engineer may require to
    demonstrate the suitability of the fill to be supplied. Imported fill shall be from a source

    ta
    approved by the Engineer. Imported fill shall have the following properties
    qa
    (a) maximum stone size of 150 mm except as specified in Clause 2.3.2 of this Part
    (b) liquid limit less than 35 %
    as

    (c) plasticity index of not more than 10.


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    3 Excavated material unsuitable for use in the Works shall not be stockpiled on the Site.
    er

    4 Disposal of excavated material not used in the Works shall be the responsibility of the
    ov

    Contractor and shall be at a location approved by the relevant government agency.

    5 Excavated material shall not be stockpiled on road reservations nor at other locations
    o

    designated in the Project Specification. The Contractor shall confine his operations to the
    it

    working areas available to him for the construction of the Works particularly where this is
    et

    located in roads or in other places to which the public has free access.
    m

    6 Stockpiling materials on the Site or off the Site, as necessary, shall be the responsibility of
    the Contractor. The stockpiling of surplus excavated material or other debris on site is not
    permitted. All surplus excavated material shall be removed from site to approved disposal
    sites. All dump trucks transporting waste shall be fully covered to prevent discharge of the
    contents.

    7 Any temporary storage alongside the trench excavation shall be to stable slopes and heights
    and deposited in such a manner that no damage and as little inconvenience as possible is
    caused. Backfilling materials shall be fenced off and continuously irrigated with water to avoid
    dust and pollution.

    8 Where the nature of the excavated material is suitable, the Contractors temporary storage
    as aforesaid shall include for separate storage as the Engineer may direct of the various
    grades of materials hereinafter specified for the refilling and surface reinstatement of trench
    or structure excavation, namely, soft material, coarse material, hard material and topsoil. The
    Contractor is to agree a screening location with the concerned municipality.
    QCS 2014 Section 08: Drainage Works Page 5
    Part 02: Earthworks

    9 The screening of trench excavated material will not be permitted on site without the written
    approval of the Engineer.

    10 The Contractor shall post signs indicating proposed use of material stockpiled. Post signs
    shall be readable from all directions of approach to each stockpile. Signs should be clearly
    worded and readable by equipment operators from their normal seated position.

    11 The Contractor shall not stockpile excavated materials near or over existing facilities,
    adjacent property, or completed work, if weight of stockpiled material could induce excessive
    settlement.

    12 The Contractor shall obtain all necessary approvals for the sites of borrow pits and quarries.
    All borrow pits shall be left in a tidy and regular state. The Contractor shall ensure that pits
    are self-draining at all times and do not constitute a nuisance and danger to the public.

    l .
    2.2.4 Excavations to be Kept Dry

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    1 The Contractor shall keep excavations free of water, sewage, and other liquids whether
    affected by tides, floods, storms, or otherwise so that the Works shall be constructed in dry
    conditions.

    2 ta
    The Contractor shall keep the subsoil or accumulated water or sewage at a level lower than
    qa
    the bottom of the permanent work until trench backfilling is complete or for such other period
    directed by the Engineer.
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    3 Measures taken by the Contractor for the control of water shall conform with the
    se

    specifications of this Part.

    2.2.5 Access
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    1 A minimum clear carriageway width of 3 m shall be maintained for vehicular traffic unless
    otherwise approved by the Engineer.
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    2 Excavations in roads shall be organised to reduce to a minimum the interval between


    it

    opening up and backfilling excavations.


    et

    3 The Contractor shall supply, post and display at all entrances to all properties a Notice of
    m

    Excavation before any excavation is undertaken in front of or in the vicinity of the property.
    The notice shall be in the form of a self- adhesive glossy sticker which shall be easily
    removable. A typical sample is shown in Section E of the Contract Documents. The
    Contractor shall remove the label after all the excavation has been backfilled.

    4 Should cess-pits of other artificial obstructions be encountered in the excavation either above
    or below ground level the Contractor shall forthwith advise the Engineers Representative
    thereof and execute at his own cost such work as may be ordered.

    5 The Contractor shall allow for laying pipes through any cess pits or septic tanks encountered
    along the route. Pipes shall be laid such that joints occur either side of the structure or in a
    manner approved by the Engineers Representative.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 02: Earthworks

    2.2.6 Trench Excavations

    1 The Contractor shall provide the necessary support of excavations. Details of excavation
    support systems shall be submitted to the Engineer for review and approval at least sixty (60)
    days before any excavation work commences.

    2 Support of excavations shall be provided in accordance with BS 6031, except as otherwise


    specified in this Part.

    3 The term necessary support of excavations covers all normal methods of temporary
    support including timber, concrete, steel sheet piling, steel trench sheeting or other materials
    as may be approved by the Engineer. Where excavation is carried out near or under an
    existing structure or any portion of the Work, the Contractor shall prevent damage due to
    subsidence with methods approved by the Engineer.

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    4 The maximum trench width shall be as given in Table 2.1 unless otherwise shown on the

    .l.
    drawings. The width of the excavation shall be increased if necessary to provide space for

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    the trench support system; undercutting of the trench sides will not be permitted.
    Table 2.1 Maximum pipe trench width at 300mm above pipe crown
    Nominal Bore
    mm
    Maximum Trench
    Width mm mm ta
    Nominal Bore Maximum Trench
    Width mm
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    100 550 600 1350
    150 600 800 1550
    as

    200 800 1000 2000


    300 900 1200 2300
    se

    400 1000 1400 2500


    500 1250 1500 2700
    er

    If the Contractor exceeds these trench widths he shall provide plain or reinforced concrete
    ov

    cradles and /or reinforced concrete arches to the requirements shown on the drawings and to
    the approval of the Engineer at no additional cost. When directed by the Engineer, supply
    and install strong and sufficient shoring to support excavations at no additional cost.
    it o

    5 No additional payment will be made to the Contractor for working in a confined space or if the
    et

    position of the Works precludes the use of mechanical excavators or the storage of
    excavated materials next to the excavations.
    m

    6 The Contractor shall submit shop drawings of all temporary works and trench support
    systems or proprietary manufacturers catalogues detailing his proposed methods of
    construction at least one month prior to starting excavations. The shop drawings shall be
    complete with all details, design calculations, and description of construction methods. The
    Engineers approval of the Contractors submittal shall not relieve the Contractor from
    obligations under the Contract.

    7 Except as otherwise precluded by the Project Specification, the Contractor may propose to
    excavate with battered side slopes. If required by the Engineer, the Contractor shall provide
    three copies of a report which shall include relevant calculations and method statement
    demonstrating the adequacy of the proposals.
    QCS 2014 Section 08: Drainage Works Page 7
    Part 02: Earthworks

    8 In the event of any trench being excavated with battered or stepped sides, that portion of the
    trench which extends from the formation to a point not less than 300 mm above the crown of
    the pipe when laid in its correct position shall be formed with vertical sides. Support shall be
    provided to the vertical trench sides to prevent ground movement. Where temporary trench
    supports are provided they shall be such that no ground movement occurs on removal.

    9 Where battered sides are proposed, no excavation work shall begin until the Engineers
    approval has been obtained. The Engineers approval shall not relieve the Contractor from
    his obligations under the Contract.

    10 The line and level of trenches shall be as shown on the Drawings and shall be maintained in
    accordance with the following procedure:

    (a) before beginning trench excavations, the route of the pipeline shall be surveyed and
    set out accurately and the existing ground level shall be agreed with the Engineer

    l .
    .l.
    (b) sight rails shall then be fixed and maintained at each change of gradient, and at as
    many intermediate points as may be necessary. The centreline and the level to which

    rw
    the excavation is to be carried out shall be marked on the site rails and the rails shall
    not be more than 20 m apart
    (c)
    ta
    alternate methods to maintain line and level of excavations shall be subject to the
    approval of the Engineer.
    qa
    11 Trench excavation shall be carried out as follows:
    as

    (a) trench excavation shall be carried out by such methods and to such lines, dimensions
    and depths as shall allow for the proper construction of the Works
    se

    (b) trench widths shall conform with the limits shown on the Drawings, or ,in the case of
    flexible pipes, to the widths stated in the Contractors approved methods statement.
    er

    Where trench widths do not conform to the limits shown on the Drawings, the Engineer
    ov

    will direct the Contractor as to the measures to be taken to remedy the situation. Such
    remedial works shall be carried out by the Contractor as an obligation under the
    Contract at no additional cost to the Employer
    o

    (c) rock encountered in trench excavations shall be so excavated that the clearance
    it

    between the pipe, when laid, and the rock sides and bottom of the trench is kept to
    et

    the minimum limits necessary to provide for the specified thickness of bedding and
    m

    where provided the concrete protection of the pipe


    (d) bell holes and holes and depressions for couplings, valves and the like shall be
    excavated the same distance below these installations as specified for the pipe.
    (e) When the trench width measured 300mm above the crown of the pipe exceeds the
    maximum allowable shown on the drawings for granular surround the Contractor shall
    proceed as Clause 4.3.2 of this Section.

    12 Limitations on the lengths of opened trenches shall be as follows:

    (a) no length of trench excavation shall begin until the pipes and fittings to be laid in the
    length of excavation are available at the Site.
    (b) the Engineer reserves the right to direct the Contractor on the lengths of trench
    which shall be excavated at any one time
    (c) the Contractor shall not be permitted to excavate trenches in more than one location
    in any road at a given time without the Engineers approval
    QCS 2014 Section 08: Drainage Works Page 8
    Part 02: Earthworks

    (d) in areas accessible by the public, the maximum length of open trench in any one
    section shall not exceed 100 m. In other areas the trench shall be dug only so far in
    advance of pipe laying as the Engineer shall permit.

    13 The Contractor shall at his own expense remove from the Site all unsuitable and excess
    material resulting from excavations beyond that required for the foundation, lining or bedding
    and shall make good the same with concrete or suitable fill material as may be required by
    the Engineer.

    14 The Engineer will inspect ground condition, or trench formation level and may direct the
    Contractor to remove additional material and to refill the excavation with concrete or other
    approved material. Should any acceptable native material at the foundation level
    subsequently become unsuitable the Contractor shall remove it and replace it with concrete
    or other suitable material as directed by the Engineer at no additional cost to the Employer.

    l .
    15 If utility obstructions are encountered during excavation and cannot be diverted, the

    .l.
    Contractor shall make the necessary changes to the design drawings and submit to the

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    Engineer for approval. The Contractor shall not make any deviation from the specified lines
    or grade of the tunnel without written approval from the Engineer.

    16
    ta
    Excavation shall be carried out to the dimensions, depths or levels in such a manner as to
    avoid excavation of or disturbance of material below grade.
    qa
    17 Pipes of greater strength or the use of superior pipe bedding may be used in lieu of
    as

    maintaining the maximum trench widths shown in Table 2.1 or specified for various pipe
    diameters, subject to the Engineers prior written approval.
    se

    18 The Contractor shall excavate trenches to the levels that will allow for the pipe wall thickness
    and bedding thickness.
    er

    19 The Contractor shall leave a clear space as approved by the Engineer, between the edge of
    ov

    the excavation and the inner toes of the spoil banks.


    o

    20 The Contractor shall grade the trench bottom with hand tools, remove loose and disturbed
    it

    material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for
    et

    bedding material if shown on the design drawings or as specified.


    m

    21 The Contractor shall remove soft sub-grade that may cause pipe settlement and replace with
    suitable backfill compacted in layers not exceeding 150 mm.

    22 The bottom of excavations for permanent structural works shall be free from mud and water,
    trimmed clean, protected from the effects of the weather and consolidated to achieve the
    required bearing capacity prior to the placement of structural work or construction materials
    within the excavation.

    2.2.7 Appurtenant Structures for Pipelines

    1 The Contractor shall carry out the necessary excavations to accommodate appurtenant
    structures such as manholes, chambers and thrust blocks. The requirements for the
    completion of excavations and handling of excavated material shall be as specified above for
    trench excavations shall apply.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 02: Earthworks

    2.2.8 Excavation in Roads

    1 In addition to the foregoing and the provisions of Section 1, pipeline excavation in roads and
    highway reserves including the provision of public safety facilities including barriers and
    enclosures shall be in accordance with the Code of Practice and Specification for Road
    Openings in the Highway published by the Highway Maintenance Section, Roads
    Department, Ministry of Municipal Affairs and Agriculture (MMAA).

    2 Where trenches are excavated open cut in roads, the asphalt shall be saw cut along the
    edges of the trench, prior to excavation.

    3 In the lanes of the road that remain open to traffic, road drains and channels shall be kept
    free from construction materials, debris and obstruction at all times.

    4 Normally trench excavation along roads shall be located in the service reserves or verges

    l .
    adjacent to the road rather than in the carriageway itself. Trench excavation shall wherever

    .l.
    practicable be carried out in such a way that every part of the excavation is at least 1 m clear

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    of the existing edge of the carriageway. The Contractor shall obtain information regarding
    utilities reservations from the Planning Department of the Ministry of Municipal Affairs &
    Agriculture and refer to their publication entitled Road Hierarchy: General Guidance for Road
    Cross-Sections and Utilities Disposition.
    ta
    qa
    5 The Contractor shall take special precautions, which includes the continuous support of the
    sides of the excavation, from the start of excavation until the refilling and compaction of the
    as

    trench backfill material is completed.


    se

    6 The Engineer may direct the trench excavation to be realigned from that shown on the
    Drawings to facilitate the flow of traffic.
    er

    7 Where trench excavation or any other part of the Works obstructs any footpath or right-of-
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    way, or property access, the Contractor shall provide, at his own cost, a temporary access
    around the obstruction to the satisfaction of the Engineer. Where applicable, this temporary
    access shall include stout wooden bridges with hand rails and kick boards or other approved
    o

    construction across any open trench. Suitable steel road plates shall be provided and
    it

    maintained where vehicle access is deemed necessary.


    et

    8 No excavated material shall be permitted to be deposited or stockpiled in grassed or planted


    m

    areas. The Contractor shall immediately remove excavated material to a temporary storage
    area and import selected approved materials for the trench filling operations.

    9 Where excavated material has temporarily been deposited on a verge, the verge shall on
    completion of backfill be restored to its original condition and left free from debris.

    2.2.9 Excavation in Areas Other Than Road Reserves

    1 Areas other than road reserves shall include but not be limited to cultivated areas,
    undeveloped areas, footpaths, verges, non-asphalt roads, lanes, alleys, and all private lands.

    2 The Contractor shall take measures to prevent access of unauthorised persons, the general
    public and animals to areas in which there are open excavations, access routes and steep or
    loose slopes arising from the Contractors operations.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 02: Earthworks

    3 The Contractor shall provide adequate temporary barriers and fencing. When necessary,
    barriers and fencing shall be illuminated.

    4 Temporary barriers and fencing shall not be removed without the Engineers written
    permission, which will not normally be given until the trench excavation has been refilled and
    reinstated.

    2.2.10 Support of Excavations

    1 The Engineer reserves the right to direct the Contractor to take measures to augment the
    Contractors proposals for the support of excavated surfaces. If, in the opinion of the
    Engineer, the support proposed by the Contractor is insufficient, the Contractor shall modify
    his proposals and provide trench support as directed by the Engineer. The absence of the
    Engineers direction, or action by the Contractor in accordance with the direction of the
    Engineer shall not relieve the Contractor of his obligations under the Contract.

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    .l.
    2 Shoring shall be properly maintained until in the opinion of the Engineer the permanent work

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    is sufficiently advanced to permit the shoring to be removed. The removal of shoring shall be
    carried out only under the personal supervision of a competent foreman. If the Contractor
    proposes not to remove the shoring on completion of the permanent work he shall obtain the
    Engineers prior written approval.
    ta
    qa
    3 All temporary works supporting the faces of excavations shall be removed during backfilling
    with the approval of the Engineer. Where removal is impracticable and with the approval of
    as

    the Engineer, temporary works shall be left in place. Temporary works left in place shall be at
    no additional cost to the Employer.
    se

    4 When, in the opinion of the Engineer, temporary supports need to be left in excavations to
    er

    support existing structures or the permanent Works, the Engineer may direct that temporary
    supports be left in place. Temporary supports left in place shall be at no additional cost to the
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    Employer.

    5 Underpinning, supports and other protective measures that are required for buildings,
    o

    structures and apparatus in or adjoining excavations shall be provided by the Contractor.


    it

    Such permanent or temporary works shall be of adequate design and construction. When
    et

    directed by the Engineer, the Contractor shall submit his methods statement for such work
    for the approval of the Engineer. The Engineers approval shall not relieve the Contractor
    m

    from his obligations under the Contract.

    6 Damage to the Works and any consequential damages caused by the removal of shoring are
    the responsibility of the Contractor. Permission or approval by the Engineer to remove
    shoring shall not relieve the Contractor from this responsibility.

    2.2.11 Slips and Falls and Excess Excavation

    1 Slips and falls in trenches shall be prevented as follows:

    (a) the Contractor shall effectively support the sides of all trench excavation to prevent
    slips and falls of material in the excavation. Support may include the use of closed
    sheeting or steel sheet piles, where necessary, to prevent any fall or run from any
    portion of the ground outside the excavation into the trench and to prevent settlement
    of or damage to existing services and structures next to the excavation
    QCS 2014 Section 08: Drainage Works Page 11
    Part 02: Earthworks

    (b) any excavation carried out by the Contractor to prevent slips and fall, or should
    portions of trench walls slip or fall away, the Contractor shall at his own expense take
    all necessary remedial measures including the excavation removal and reinstatement
    of all the ground thereby disturbed
    (c) in all cases where the voids so formed when backfilled would provide support for the
    permanent Works or adjacent structures and services, such voids shall be filled
    with Grade 20 SRC concrete at the Contractors expense. In all other cases the voids
    shall be filled with selected excavated material compacted as specified in this Part.

    2.2.12 Trimming and Levelling

    1 No excavation shall be filled in or covered with concrete until it has been inspected by the
    Engineer.

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    2 Where shown on the Drawings or instructed by the Engineer, a layer of blinding concrete
    shall be placed to the required thickness to protect the formation and provide a clean working

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    surface.

    3 The Contractor shall compact the formation before placing the blinding concrete, when in the
    ta
    opinion of the Engineer the formation density can be improved by compaction.
    qa
    4 When excavating to specified levels for trench excavation for pipelines, or to specified limits
    for the face of any thrust block or other structure required to abut or to rest upon undisturbed
    as

    ground, excavations shall be trimmed as follows:


    se

    (a) the Contractor shall not excavate the last 150 mm until immediately before beginning
    construction work except where the Engineer permits otherwise. Should the
    er

    Contractor have excavated to within 150 mm above these specified levels or to within
    150 mm of these specified limits before he is ready or able to commence the
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    construction work he shall where required by the Engineer excavate further so as to


    remove not less than 150 mm of material immediately before commencing the
    construction work and any such further excavation and additional foundation material
    o

    ordered by the Engineer shall be at the cost of the Contractor. The last 150 mm shall
    it

    be hand excavated
    et

    (b) the bottom of excavations shall be carefully boned in and trimmed true to grade with
    m

    the aid of a straight-edge.

    2.2.13 Excavations Not to be Left Open

    1 Trench excavation shall be carried out expeditiously in the following manner:

    (a) the refilling and surface reinstatement of trench excavations shall begin and be
    completed as soon as reasonably practicable after the pipes have been laid and
    jointed
    (b) the Contractor shall take precautions to prevent flotation of pipes in locations where
    open trench excavations become flooded, and these precautions shall include the
    partial refilling of the trench leaving pipe joints exposed for tests of the joints
    QCS 2014 Section 08: Drainage Works Page 12
    Part 02: Earthworks

    (c) if the Engineer considers that the Contractor is not complying with the foregoing
    requirements, The Engineer will not permit further trench excavation until he is
    satisfied with the progress of laying and testing of pipes and refilling of trench
    excavation.

    2.2.14 Dewatering of Excavations

    1 For construction dewatering refer to Section 1 Part 24 Construction Dewatering.

    2 The Contractor shall submit methods statements including drawings and data showing the
    intended plan for dewatering operations. Details of locations and capacities of dewatering
    wells, well points, pumps, sumps, collection and discharge lines, standby units, water
    disposal methods, monitoring and settlement shall be included. The methods statement shall
    be submitted to the Engineer for approval not less than 30 days before the start of
    dewatering operations. The Engineer reserves the right to reject the proposal if he is not

    l .
    satisfied with measures.

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    3 The Contractor shall satisfy himself on the scope of dewatering necessary for the
    construction of the Works and shall make the necessary investigations to obtain the required
    data and information.

    4 ta
    Where necessary, the Contractor shall divert natural and artificial waterways encountered at
    qa
    the Site until the Works are completed.

    5 The Contractor shall perform dewatering as necessary to ensure that


    as

    (a) the Works are installed on dry areas and excavations, including without limitation the
    se

    construction of all structures and underground piping


    er

    (b) dewatering is carried out only to a depth sufficient for the required excavation
    (c) during construction, no groundwater shall come into contact with any concrete surface
    ov

    or reinforcement
    (d) structures shall be capable of withstanding any hydrostatic pressure to which it may
    o

    be subjected during construction and until completed.


    it
    et

    6 The Contractors dewatering operations shall be conducted so as not to endanger the


    foundations or stability of the Works or any adjacent structures. Damage caused by the
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    Contractors operations shall be made good by the Contractor at no additional cost to the
    Employer.

    7 Discharge of groundwater from excavations to the sea, into surface storage ponds or deep
    well recharge shall require the approval of the Ministry of Environment.

    8 Water removed from excavations shall first pass through settlement tanks and on-site
    treatment prior to discharge.

    9 Unless otherwise approved by the Engineer, wellpoint dewatering systems shall be provided
    on both sides of trenches.
    QCS 2014 Section 08: Drainage Works Page 13
    Part 02: Earthworks

    10 The static water level shall be drawn down a minimum of 300 mm below the bottom of the
    excavation so as to maintain the undisturbed state of the foundation soils and allow the
    placement of any fill or backfill to the required density. The dewatering system shall be
    installed and operated so that the groundwater level outside the excavation is not reduced to
    the extent that would damage or endanger adjacent structures or property.

    11 The Contractor shall, where extensive dewatering is required, be fully qualified to perform the
    dewatering operations or shall furnish the services of an experienced, qualified, and
    equipped dewatering subcontractor to design and operate the dewatering and groundwater
    recharging system required for the work, all subject to the Engineers approval.

    12 When directed by the Engineer, the Contractor shall establish a specified number of
    groundwater level monitoring stations at each site which shall be observed during the work.
    These shall be located as directed by the Engineer and consist of acceptable open tube
    piezometers. When directed by the Engineer, the Contractor shall provide settlement gauges

    l .
    to the approval of the Engineer and monitor settlement of new and existing facilities.

    .l.
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    13 Dewatering shall not result in the flow of water along the pipe zone material. Full
    consideration should be given to the use of cut-off walls to reduce the potential for
    groundwater flow along pipe trenches. The Contractor shall submit for the Engineers

    ta
    approval, details of his proposed method of working and temporary works installations to
    qa
    achieve this.

    14 If the use of drainage conduits, channels or subdrains is approved by the Engineer and are to
    as

    be left in place below the level and within the width limits of permanent Works they shall be
    structural capable of providing support. Ballast filled subdrains to be left in place under
    se

    concrete shall be covered with a geotextile membrane. Subdrains left in place shall be filled
    with Grade 20 SRC concrete or an approved cementitious grout.
    er

    15 The release of groundwater to its natural static level shall be performed so as to maintain the
    ov

    undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or
    backfill and prevent floatation or movement of structures, pipelines and sewers.
    o

    16 No dewatering system shall be removed until infiltration testing is completed nor without the
    it

    approval of the Engineer. Monitoring and settlement measurement systems shall be


    et

    maintained in operation until removal is approved by the Engineer. With the approval of the
    m

    Engineer, wellpoints and like items may be abandoned in place.

    17 Partially completed permanent works shall not be allowed to become flooded and the
    Contractor shall allow for additional standby pumps and equipment required to ensure this. A
    pump operator shall be on site 24 hours per day to supervise pumping equipment.

    18 In the event of partially completed trenches becoming flooded, the Contractor shall re-
    excavate to formation level and re-lay the pipes.

    19 The Contractor shall provide a silt-trap in any temporary drain which he may construct and
    prior to discharge into any permanent drain which he may wish to use for the removal of
    water during the construction period. The Contractor shall keep both temporary and
    permanent drains clear of silt to the satisfaction of the Engineer until the completion of the
    Contract. Any silting up of the watercourses arising from the Contractors failure to comply
    with this Clause shall be remedied at his expense whether within the Site or not.

    2.3 BACKFILL
    QCS 2014 Section 08: Drainage Works Page 14
    Part 02: Earthworks

    2.3.1 Pipe Bedding

    1 Pipe bedding shall be provided as shown on the Drawings or stated in the Contractors
    approved methods statement.

    2 Pipe bedding shall be well compacted to a minimum void ratio to provide a high load-bearing
    capacity and a stable base below the pipe and shall completely fill the whole width of the
    trench excavated. Compaction requirements equivalent to at least 90 percent of the Standard
    Proctor Maximum Dry Density shall be achieved. Additional bedding necessary to fill voids
    created by over excavation shall be provided entirely at the Contractors expense.

    3 Pipe bedding shall consist of granular material and shall shall conform with the following
    requirements:

    (a) shall be free of organic and deleterious matter and shall consist of strong durable

    .
    crushed un-weathered rock or stones having roughly cubical or pyramidal shaped

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    fragments, graded and tested from a source approved by the Engineer. No reactive

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    carbonate rock or sources with indication of local groundwater contamination shall be
    used.
    (b) pipe bedding material for rigid pipes shall be according to the following grading limits
    giving in Table 2.2.
    ta
    qa
    Table 2.2 Gradation Requirements for Pipe Bedding, Rigid Pipes
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    <300 300 - 800 >800


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    Sieve Size % by Mass % by Mass % by Mass


    Passing Passing Passing
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    25mm - - 100
    20mm - 100 90 - 100
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    14mm 90 - 100 80 - 100 50 80


    10mm 50 - 85 60 - 85 40 70
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    5mm 10 - 40 20 - 55 25 60
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    2.36mm 0 - 10 10 - 30 10 40
    et

    0.300 - 0 - 10 0 - 15
    m

    (c) The minimum thickness of pipe bedding material below the barrel of the pipe is given
    in Table 2.3.
    Table 2.3 Minimum thickness of bedding material below barrel of pipe
    Uniform Soil
    Nominal Bore
    Hand Finished Machine Dug Rock
    (mm)
    Trench Bottom Trench Bottom
    100 & 150 100 150 200
    200 - 500 150 200 250
    600 - 800 175 225 275
    1000 & above 200 250 300
    (d) Pipe bedding and backfill to French drains shall be in accordance with Section 6, Part
    14, Clause 14.9.5.
    QCS 2014 Section 08: Drainage Works Page 15
    Part 02: Earthworks

    (e) The total loss factor for the granular material used in French drains using the ten
    minute rotational test shall not exceed 10%.
    (f) Chloride and sulphate levels for bedding materials shall conform to BS EN 10319.

    4 Pipe bedding material for flexible pipes be accoding to the following grading limits given in
    Table 2.4.
    Table 2.4 Gradation Requirements for Pipe Bedding, Flexible Pipes
    Pipe Diameter (mm)
    Sieve Size <300 300
    % by Mass Passing % by Mass Passing
    14mm - 90 - 100
    10mm 50 - 85 50 - 85
    5mm 10 - 40 0 - 10

    .
    2.36mm 0 - 10 0 - 10

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    The minimum thickness of granular bedding material around the barrel of the pipes shall be
    100mm. Should the Contractor exceed the trench widths given in Table 2.1 he shall precede
    as Clause 4.3.2 of this Section.

    5 ta
    The design of GRP and PE pipes and bedding is specified in Parts 3 and 4 of this Section.
    qa
    Granular bedding materials for GRP pipe shall be 10mm nominal size according to the
    grading limits given in Table 2.4 and also meet the manufacturers requirements.
    as

    6 After trimming and compaction of the formation, granular bedding material shall be spread in
    se

    the trench bottom.

    7 Cut-off walls shall be formed in granular bedding and surround to pipes to prevent the
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    bedding acting as a subsoil drain. Cut-off walls shall be provided at a maximum spacing of
    ov

    40 m with one at each manhole and structure and at least one cut-off wall between two
    adjacent manholes and structures.
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    8 Cut-off walls shall be made from an impervious fine grained clay mixture, prepared with
    it

    addition of water where necessary, to suitable trench spoil if available, or imported. Concrete
    et

    cut-off walls shall be Grade 20 SRC concrete. Cut-off walls shall be installed across the full
    cross-section of the granular bedding material and shall be at least 300 mm wide along the
    m

    axis of the pipeline.

    9 Concreting to the pipeline shall be either bed or bed and surround or encasement or backfill
    as shown on the Drawings or directed by the Engineer and shall be of Grade 20 SRC
    concrete placed as follows:

    (a) concrete shall not be placed until the joints at each end of the pipe have been
    completed
    (b) each pipe to be encased shall be supported on at least two purpose made precast
    concrete blocks, which shall be left in place
    (c) concrete encasement shall be placed to the required depth in one operation and pipes
    shall be prevented from floating or otherwise moving during concreting
    (d) continuity of concrete backfill or encasement to pipe with flexible joints shall be
    broken at each joint, unless otherwise approved by the Engineer
    QCS 2014 Section 08: Drainage Works Page 16
    Part 02: Earthworks

    (e) flexible joints in concrete beds and surrounds to pipes shall be formed as shown on
    the Drawings with suitable compressible fibrous board or other similar approved
    material
    (f) compaction shall be carried out with approved mechanical vibrators. The maximum
    period of time between mixing of the materials and final compaction of any given
    material shall be kept to a minimum.

    10 Where unstable ground conditions are met which are likely to cause undue settlement in the
    pipeline, the Contractor shall submit a report including site data and the Contractors proposal
    for remedial works including structural calculations for the approval of the Engineer. The
    Contractor shall carry out the following remedial works as directed by the Engineer.

    (a) improvement of mechanical properties of the soil


    (b) replacement of soil by other soil or blinding concrete

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    (c) pile foundations

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    (d) reinforced concrete slab foundation.

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    2.3.2 Pipe Surround

    1
    approved method statements. ta
    Pipe surround shall be provided as shown on the Drawings or stated in the Contractors
    qa
    2 When concrete cradles are used, all concrete shall have attained adequate strength before
    backfilling of the excavation commences between the completed structure and sides of
    as

    excavations.
    se

    3 Material for pipe surround and to the first 300mm above the top of the pipe, shall be granular
    material as specified in Clause 2.3.1. The material shall be free from sharped edged stones
    er

    or other material which may cause damage to the permanent Works.


    ov

    4 Material for pipe surround shall be placed in layers of not greater than 150mm compacted
    thickness and thoroughly rammed with suitably shaped rammers working alternatively on
    either side of the pipe until the fill has been carried up at least 300mm above the top of the
    o

    pipe. Care shall be taken to avoid damage to the pipe, coating or sheathing.
    it
    et

    5 Compaction requirements equivavlent to at least 90 percent of the Standard Proctor


    Maximum Dry Density shall be achieved.
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    2.3.3 Geotextile Filter Membrane

    1 Geotextile filter membrane for surround to granular material for ground water drainage shall
    conform with the requirements of Section 6 Part 15 Clause 15.1 and shall be used in the
    zone extending downwards from 1.5m above the long term water table. The long term water
    table is to be determined on the basis of observations made on site of the initially
    encountered water table in the excavations. The placement of Geotextile is then to be
    directed by the Engineer. Geotextile membrane for structural support to pipe surround in soft
    ground shall be wrapped round the granular bedding as shown on the Contract drawings.

    2 For both of the above applications the geotextile properties shall be:

    (a) mean peak strength BS EN ISO 10319 8kN/m


    (b) elongation at peak strength BS EN ISO 10319 28%
    (c) CBR puncture resistance EN ISO 12236 1500N
    QCS 2014 Section 08: Drainage Works Page 17
    Part 02: Earthworks

    (d) pore size (O90) EN ISO 12956 0.15mm


    2
    (e) permeability (50cm head) EN ISO 11058 100l/m .s

    3 The fabric shall be woven or non-woven consisting of long chain polymeric filaments or yarns
    formed into a stable network such that the filaments or yarns retain their relative position to
    each other.

    4 The fabric shall be inert to commonly encountered chemicals and chemical properties of the
    soil and water. Geotextile fabric shall surround the granular bedding as follows:

    (a) the surface to receive the fabric shall be formed to a relatively smooth condition free
    of obstruction, depressions, and debris. The geotextile fabric shall be laid loosely.
    (b) if the proposed area for fabric requires more than one panel width of fabric, the
    panels shall be overlapped a minimum of 15 percent of the panel width

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    (c) to prevent slippage of the overlapping fabric, the areas of overlap shall be stabilised,

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    as approved by the Engineer, with pins, anchor blocks, or piles of aggregate

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    (d) fabric damaged or displaced before or during installation or during placement of
    backfill material shall be repaired or replaced

    2.3.4 Backfilling Excavation


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    1 All concrete shall have attained adequate strength before backfilling of the excavation
    commences between the completed structure and sides of excavations.
    as

    2 Selected fill material for trench backfill in open areas, shall be suitable material selected from
    se

    the excavated material as specified in Clause 2.2 of this Part. Stones larger than 150 mm in
    size may be allowed, provided in the opinion of the Engineer, the required densities can be
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    achieved.
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    3 Selected fill material for trench backfill under paved areas, shall be suitable material selected
    from excavated materials meeting the following requirements:
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    (a) maximum stone size of 75m


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    (b) the material passing the 0.063 sieve shall be less than 15%
    et

    (c) the liquid limit shall not exceed 35% and the plasticity index shall not exceed 6%
    m

    (d) the uniformity coefficient shall not be less than 10


    (e) the total water soluble / acid soluble salt content (for sulphate and chloride) shall not
    exceed 2%
    (f) organic content shall not exceed 2%
    (g) the CBR value shall not be less that 15% at 95% maximum dry density at the formation
    level. The test procedure shall be as Section 6, Clause 3.10 of the specification.

    4 The trench backfill material shall be placed in layers of not greater depth than 200mm
    thickness and be thoroughly compacted to 95 percent of the Standard Proctor Maximum Dry
    Density by approved mechanical compaction equipment. In roads and footpaths, the coarse
    filling is to be carried up to the level at which surface reinstatement is to begin; elsewhere, to
    such level as with the surface reinstatement of the whole of the topsoil will leave the finished
    work sufficient to allow for future settlement to the original ground level.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 02: Earthworks

    5 The moisture content of the material before compaction shall not vary by more than 2% of
    the optimum moisture content (BS 1377 Part 2:1990, Test 3.2). If in the opinion of the
    Engineer, the fill is too dry, it shall be watered at the expense of the Contractor in an
    approved manner during refilling as may be directed by the Engineer.

    6 Any nuclear density measurement (NDM) tests undertaken shall be performed only by
    persons or companies holding a valid Authorised User Certificate issued by the Materials
    Central Laboratory. Each NDM device shall have a valid Calibration Certificate, also issued
    by the Central Materials Laboratory.

    7 The Contractor shall provide the necessary testing apparatus for monitoring soil properties
    and shall maintain the apparatus in good working order. A daily log of tests carried out shall
    be provided to the Engineer. Testing of soil properties shall be carried out by an approval
    laboratory.

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    8 Tests to determine the optimum dry density of the fill material shall be carried out as directed

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    on site, the frequency depending on consistency of material and test results.

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    9 Unless directed otherwise, testing for density and moisture content shall be at the rate of:

    (a)
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    one test per backfill layer for each structure such as manholes, chambers, and thrust
    blocks
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    (b) one test per backfill layer for every 30 m of pipeline trench.
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    10 Should the backfilling material being placed become unacceptable to the Engineer due to

    (a) exposure to weather


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


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    (d) otherwise unacceptable during the progress of work


    the Contractor shall at his own expense remove such damaged, softened or
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    segregated material and replace it with fresh approved material.


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    11 To permit the proper consolidation of backfill into the voids behind trench sheeting and
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    supports, trench sheeting shall be withdrawn gradually as backfill progresses in depth and
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    along the trench.

    12 On no account shall any excavated material be dozed back when filling trenches in roads and
    no filling shall be carried out unless in the opinion of the Engineer, sufficient mechanical
    compactors are in operation on that portion of the work.

    13 Where in the opinion of the Engineer sufficient supplies of the suitable material for trench
    backfilling cannot reasonably be obtained from excavations the Engineer may order the
    Contractor to:

    (a) carry out such work as may be necessary to screen out stones
    (b) borrow excavate material from suitable borrow areas on the Site or off the Site and
    transport it to the length of trench to be filled to the approval of the Engineer.
    All costs for borrow material shall be borne by the Contractor.
    QCS 2014 Section 08: Drainage Works Page 19
    Part 02: Earthworks

    14 Trench backfilling shall be carried out expeditiously as soon as practicable after the pipeline
    has been laid, tested and approved.

    15 Trench bottom shall be free of any foreign material or backfill contaminated with foreign
    material from the trench bottom.

    16 Check grade and correct irregularities in bedding material. Loosen top 25-50 mm of
    compacted bedding material with a rake or by other means to provide a cushion before laying
    each section of pipe, conduit, direct-buried cable, or duct bank.

    17 Place backfill material simultaneously in lifts on both sides of pipe and, if applicable, between
    pipes, conduit, cables, and duct banks installed in the same trench.

    (a) Pipes up to and including 250 mm in diameter: First lift of backfill less than or equal to
    1/2 pipe diameter.

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    (b) Pipe over 250 mm in diameter: Maximum 150 mm lifts.

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    18 Thoroughly tamp each lift, including the area under haunches, with handheld tamping bars
    supplemented by walking in and slicing material under haunches with a shovel to ensure
    that voids are completely filled before placing each succeeding lift.

    19 ta
    After the full depth of the pipe zone material has been placed as specified, compact the
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    material by a minimum of three passes with a vibratory plate compactor only over the area
    between the sides of the pipe and the trench walls.
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    20 Do not use power-driven impact compactors to compact pipe zone material.


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


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    2.3.5 Backfilling Excavations with Cement-Bound Granular Material

    1 Backfilling excavations with cement-bound granular material shall be used for filling
    excavations at manholes, access shafts, pipe line structures in roadways, underneath
    exposed existing pipelines or as approved by the Engineer.

    2 Cement-bound granular material shall consist of crushed, hard, clean, durable rock or
    washed sand or a combination thereof. The material shall be sufficiently well-graded to
    ensure a well-closed surface finish and have a grading within the range shown in Table 2.4

    Table 2.4 Grading for cement-bound granular material

    BS 410 sieve size Percentage by Mass Passing


    50 mm 100
    37.5 mm 95 - 100
    20 mm 45 - 100
    QCS 2014 Section 08: Drainage Works Page 20
    Part 02: Earthworks

    10 mm 35 - 100
    5 mm 25 - 100
    600 m 8 - 65
    300 m 5 - 40
    75 m 0 - 10

    3 The granular material shall be mixed with sufficient cement to provide the crushing strength
    specified in Paragraph 12 of this Clause. The material shall be mixed in a paddle or pan type
    mixer which may be batch or continuous type. Where a batch mixer is used, the mixing times
    shall not be less than one minute unless the Engineer approves a shorter time subject to the
    results of preliminary trials. Where a continuous mixer is used, the paddles, baffles and rate
    of feed of materials shall be adjusted to provide a uniformly mixed material. Where a spray
    is used for distributing water into the mixer, it shall be adjusted to provide a uniform moisture
    content throughout the mix.

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    4 The moisture content of the mixed material shall not exceed 2 % above the optimum as
    determined in accordance with the Vibrating Hammer Test of BS 1924.

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    5 The Contractor shall carry out preliminary tests on trial mixes to attain the specified crushing
    strength.
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    6 Plant-mixed material shall be transported to the site by vehicles which shall have capacities
    suited to the output of the mixing plant and site conditions, and be capable of clean
    discharge. Mixed material shall be immediately transported to its required location and shall
    as

    be suitably protected from the prevailing climatic conditions during transportation and the
    period before tipping.
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    7 All mixed material shall be placed and immediately spread evenly in one layer such that after
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    compaction the thickness does not exceed 150 mm.


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    8 Compaction in trenches shall be carried out immediately after the material has been spread
    and completed within two hours of the addition of cement.
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    9 Compaction shall be carried out to achieve a density equivalent to 95 % of the average


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    density of the set of five cubes required for testing in paragraph 12 of this Clause.
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    10 Any layer of cement-bound granular material not covered within two hours shall, immediately
    on completion, be cured for a minimum period of 7 day unless otherwise approved by the
    Engineer or the surface is covered by permanent works. Surface curing shall be achieved by
    covering with impermeable plastic sheeting until the next permanent layer is laid. The plastic
    sheeting shall be adequately secured to the surface and joints shall be have a minimum
    300 mm overlap, set to prevent egress of moisture.
    QCS 2014 Section 08: Drainage Works Page 21
    Part 02: Earthworks

    11 Samples of the mixed material shall be taken from the site immediately before compaction of
    the material. A batch of five random samples shall be taken from each layer or such other
    area as decided by the Engineer. From each sample a cube test specimen shall be
    prepared, cured and tested using the procedure in BS 1924. The specimens shall be
    compacted to be within 95 % of the cube density when compacted by vibratory hammer. The
    specimens shall then be cured at constant moisture content within the range of curing
    temperatures stated in BS 1924 for a period of 7 days. The specimen shall then be weighed,
    the dimensions checked and tested in unconfined compression. A representative portion of
    the crushed material from each specimen shall then be retained for a moisture content
    determination in accordance with BS 1924 and the dry density of each specimen determined
    using mass, dimensions and the moisture content of the material.

    12 The average 7 days crushing strength for each batch of five test specimens made and tested
    in accordance with the method described herein shall be not less than 3.5 MPa for cubes. In
    addition to complying with the minimum strength requirements, the root mean square of the

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    coefficient of variation of the crushing strength of five successive batches of five test

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    specimens of the cement-bound granular material shall not exceed 25 %. If an area or layer

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    of cement-bound granular material represented by these specimens fails these tests, the
    defective material shall be removed and replaced with new material at the Contractors
    expense.
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    13 The cement-bound granular material shall in no case be less than 150 mm thick from the
    outside barrel of the pipe to the nearest point of the shoring, and the greatest care shall be
    exercised to ensure complete filling of all voids and thorough consolidation of the concrete.
    as

    The Contractor shall allow in his prices for the additional concrete used in excess of the net
    requirement.
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    14 Cement Bound Granular Material discharged from truck mounted drum type mixer into
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    trench shall:
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    (a) Placed in lifts as necessary to prevent uplift (flotation) of new and existing facilities.
    (b) In travelled areas, fill entire trench section to pavement finish grade for a temporary
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    driving surface, and screed off excess and finish with a float.
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    (c) In other areas, fill the trench section as shown on the Contract Drawings.
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    2.3.6 Backfilling Excavation with Flowable Fill (Foamed Concrete)


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

    2 Flowable fill may be placed by chutes, conveyors, buckets or pumps depending upon the
    application and accessibility.

    3 For trench backfill, flowable fill shall be placed continuously. To contain the flowable fill along
    long open trenches or open ended structures in stages, the end points shall be adequately
    bulkheaded to prevent movement.

    4 Flowable fill shall be placed in a manner to prevent flotation or displacement of the


    embedded item.
    QCS 2014 Section 08: Drainage Works Page 22
    Part 02: Earthworks

    5 The 28-day compressive strength of the flowable fill shall be 5 MPa with a unit density of
    3
    between 1600 2000 kg/m . Accelerators may be used subject to the approval of the
    Engineer.

    2.3.7 Backfilling Next to Pipeline Structures

    1 Fill materials adjacent to structures such as manholes and chambers shall be placed in
    accordance with Clause 2.3.4 above.

    2 Fill material next to structures other than pipeline structures shall be carried out as Specified
    in Section 12.

    2.3.8 No-Fines Concrete as Trench Backfill

    1 Except where otherwise noted in this Clause, the design, manufacture, use and testing of no-

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    fines concrete shall comply with the requirements of Section 5 Part 6.

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    2 All material shall be placed and spread evenly. The full width of the excavated trench shall be
    filled; formwork other than that required for temporary constructions joints will not be
    permitted. The Contractor shall be responsible for the use of any extra material required to fill

    ta
    the trench beyond the maximum trench widths detailed on the drawings. The no-fines
    concrete shall generally be brought up to a height no higher than the level of undisturbed rock
    qa
    on either side of the trench.
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    3 Compaction shall be carried out with approved mechanical vibrators. The maximum period of
    time between mixing of the materials and final compaction of any given material shall be kept
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    to a minimum.

    4 Any layer not covered within 2 hours by another layer of no-fines concrete shall, immediately
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    on completion of compaction, be cured for a period which shall not be less than 7 days
    ov

    unless the Engineer agrees otherwise. Curing shall be achieved by covering until the next
    layer is laid with impermeable plastic sheeting, adequately secured from being blown off the
    surface and with joints overlapped at least 300mm and set to prohibit egress of moisture.
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    2.4 REINSTATEMENT OF SURFACES


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    2.4.1 Reinstatement within the Highway

    1 All reinstatement of roadworks to be carried out in the public highway shall be carried out in
    accordance with the latest Code of Practice and Specification of Road Openings in the
    Highways.

    2.4.2 Reinstatement of Surfaces Other Than in the Highway

    1 Unless provided in the Project Specification, surfaces shall be restored to a condition


    conforming to the requirements for the particular surface described in the relevant section of
    this Specification. Where no specification exists, restoration shall be to the satisfaction of the
    Engineer.

    2 All surfaces, gardens or lawns shall be restored to a condition equal to the original surface to
    the satisfaction of all Authority requirements, the Engineer and the owners/occupiers.
    QCS 2014 Section 08: Drainage Works Page 23
    Part 02: Earthworks

    3 Any reinstatement shall be fully maintained by the Contractor until such time that a Taking-
    Over Certificate has been issued for the Works or for the Part of the Works containing the
    reinstatement.

    2.5 EXISTING SERVICES

    1 The requirements of this Subpart are in addition to the general requirements specified in
    Clause 2.1.5 of this Part.

    2 The Contractor shall be required to submit in advance to the various Utilities Services
    Departments and to the relevant Municipality where the Works affect the trees and plants
    and a weekly programme of the pipelines he intends to lay in order that the various
    departments can expose or advise on the location of their respective services.

    3 Except as otherwise designated in the Project Specification, the Contractor shall be

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    responsible for maintaining all services and utilities including but not limited to waterways,

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    sewers, drains, gas and oil mains, water mains electricity and telecommunication cables and

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    all other services, structures, trees, and plants encountered during the construction of the
    Works and for any remedial measures necessary to make good any damage caused thereto.

    4
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    Where designated in the Project Specification, work on services shall be carried out by the
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    relevant Utility Service Department. The Contractor shall co-ordinate his work with the work
    of the Utility Service Department, and carry out his work so as not to interfere with or damage
    their services.
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    5 Where work is carried out close to or across the line of existing services, the Contractor shall
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    where necessary provide temporary supports or slings. Where service is interfered with or
    damaged, the Contractor shall immediately notify the relevant Utilities Service Department
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    and shall not undertake repairs without their authorisation and approval. Unless otherwise
    authorised and approved, repairs shall be undertaken by the Utilities Service Department and
    ov

    the cost of such work shall be borne by the Contractor, and the Contractor shall reimburse
    the Utilities Service Department its account for performing such work.
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    6 Where specified on the Drawings or by the relevant Utility Service Departments split ducts,
    it

    conforming with the requirements of Clause 2.7.1 of this Part shall be provided for the
    et

    permanent support and protection of services.


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    7 The Utility Service Department and the Engineer shall determine whether or not a service
    requires to be permanently diverted, temporarily diverted or supported.

    8 Where existing services have to be permanently or temporarily diverted as the unavoidable


    result of the construction of the Works, such diversions shall be carried out either by the
    Contractor or the Utilities Service Department as directed by Engineer.

    9 Safety shall always be maintained in all work in the vicinity of existing services in accordance
    with particular requirements of Utilities Service Department and the requirements of Section
    1 and Part 1 of this Section.

    10 In addition to the provisions of the above paragraphs, when carrying out pipelaying
    operations in the vicinity of existing gas or oil pipelines, the following requirements shall
    apply:
    QCS 2014 Section 08: Drainage Works Page 24
    Part 02: Earthworks

    (a) the minimum clearance between the bottom of the oil or gas line and the top of the
    pipeline being constructed is to be 600 mm
    (b) a hand excavated pilot hole shall be dug to determine the gas or oil line invert level
    and position prior to any trench excavation in gas or oil pipeline reservation
    (c) the excavation for the pipeline under construction must be carried out by hand up to
    (d) 2.0 m either side of the existing gas or oil pipeline
    (e) manually operated jack hammers may be used within 5.0 m of the buried pipeline
    only after completion of item (c) above
    (f) the use of mechanical or hydraulic rock-breakers shall not be allowed within 5.0 m of
    the buried pipeline
    (g) before the exposure of live pipeline the Contractor is to erect a suitable substantial
    barrier to prevent damage to the exposed pipeline.

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    (h) on completion of the concrete surround to the pipelines under construction, the
    existing gas or oil pipeline shall be rebedded with a minimum of 150 mm of naturally

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    occurring soft dune sand bed and surround. The remaining backfill and bund shall be
    made up of selected desert fill with a particle size not exceeding 150 mm which shall

    ta
    be free from organic matter. The Qatar Petroleum (QP) (onshore) Engineer shall be
    notified a minimum of 24 h in advance, to witness the backfilling operation
    qa
    (i) damage to the external protective wrapping to the gas or oil pipeline shall be reported
    promptly to the QP who will arrange for the damage to be inspected and repaired
    as

    in strict accordance with QP (onshore) procedures at the Contractors cost


    (j) the Contractor is to provide constant competent supervision whilst work is carried out
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    next to the existing gas or oil pipelines


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    (k) when the works reach 15 m from the existing gas or oil pipeline, the Contractor shall
    contact the QP (onshore) Engineering Superintendent, who will arrange the necessary
    ov

    permit to work. QP (onshore) will require a minimum of 48 h notice before work begins
    (l) a QP (onshore) permit to work does not in any way make QP (onshore)
    o

    responsible for any of the Contractors work, nor does it absolve the Contractor from
    it

    his responsibilities for complying with the above, but only allows the Works to be
    et

    carried out in accordance with the agreed working methods and practices. QP
    (onshore) reserve the right to visit the site regularly to observe that the agreed
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    methods and practices are being adhered to and to stop the work and withdraw the
    permits to work should they consider there is adequate justification to do so
    (m) the requirements of QP (onshore) may vary from and are not necessarily limited
    to the foregoing.

    2.6 BLASTING

    1 The Contractor shall not use any explosives in the construction of the works without the prior
    written approval of the Engineer and such approval shall be contingent upon the Contractor
    being authorised by the Civil Defence Department and the Police.
    QCS 2014 Section 08: Drainage Works Page 25
    Part 02: Earthworks

    2 The Contractor shall inform the Engineer in advance about the types and quantities of
    explosives needed. Explosives shall be obtained and used in accordance with the regulations
    and procedures of the relevant Government Department. The Contractor shall be deemed to
    have copies of relevant documentation and to be knowledgeable of relevant practices. The
    Contractor shall provide copies of relevant documentation to the Engineer for the Engineers
    inspection.

    3 Notwithstanding the requirements of this Clause, the Contractor is responsible for the safe
    and correct transport, handling and use of explosives.

    4 Except as otherwise provided in the relevant regulations and procedures the handling of
    explosives shall be carried out to conform with the requirements stated in the following
    paragraphs.

    5 Except as otherwise permitted by the Government, all unused explosives, or explosive

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    accessories shall be destroyed at the end of each days work.

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    6 Explosives and detonators shall be carried in separate vehicles during transport. The
    vehicles must be clean and in a good state of repair and be of sufficient capacity to convey
    the explosives safely. The Police may refuse to issue explosives if vehicles do not meet

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    those standards. A red flag must be clearly displayed by all vehicles when carrying
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    explosives.

    7 The Contractor must appoint in writing at least one shotfirer who is in possession of a Qatar
    as

    Shotfirers Certificate of Competence to carry out all work with explosives on behalf of the
    Contractor. The Contractor shall present and provide copies of such certification to the
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    Engineer for inspection.


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    8 The Contractor must establish simple safety rules covering the handling and use of
    explosives. A copy of these rules will be given to the concerned shotfirer, who will sign a
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    receipt book kept for this purpose by the Contractor.

    9 The safety rules shall specify:


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    (a) the places where explosives are to be used


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    (b) times of blasting


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


    (d) method of initiation
    (e) posting of warning notices, yellow blasting flags and sentries; and audible warning, if
    applicable
    (f) actions to be taken in the event of any unusual occurrence or accident
    (g) any other safety aspects relating to the use of explosives
    (h) any special instructions concerning transport
    (i) instructions relating to the limitation of blast vibrations, where appropriate.

    10 The Contractor shall submit a copy of the safety rules to the Engineer.
    QCS 2014 Section 08: Drainage Works Page 26
    Part 02: Earthworks

    11 Shotfirers shall be responsible to the Contractor for ensuring that all explosives and
    accessories are safely and carefully handled and used, in accordance with the regulations
    and procedures of the Government, and his own knowledge of correct shotfiring procedure.

    12 Where so directed by the Engineer, the Contractor shall provide and operate suitable
    instruments to monitor and record the blast vibrations at no additional cost to the Employer.

    13 Where blasting vibration could cause nuisance; e.g., in close proximity to buildings, pipelines
    or other structures, the Contractor shall ensure that careful attention is given to the vibration
    levels to minimise nuisance.

    2.7 MISCELLANEOUS

    2.7.1 Service Ducts

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    1 The Contractor shall furnish and install new protection ducts of split PVC-U pipes, concrete

    .l.
    encased, to protect existing utility mains or cables where new pipelines are to cross such

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    utility mains or cables.

    2 After the split PVC-U pipe has been placed around the existing utility mains or cables, the

    ta
    pipe shall be wrapped twice with polyethylene film, 150 m thick, to prevent fresh concrete
    qa
    from entering the duct. The protection ducts shall be supported on suitable non-corrosive
    spacers before placing the concrete encasement.
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    3 All concrete work shall be in accordance with the requirements of Section 5 and concrete
    encasement shall be with Grade 20 SRC concrete.
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    2.7.2 Formation of Bunds and Embankments


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    1 The material used in the formation of embankments bunds and other areas of fill shall be
    ov

    obtained by the Contractor from sources approved by the Engineer. The material shall
    equate to selected excavated material or similar.
    o

    2 Bund and embankment material at the optimum moisture content shall be built up evenly
    it

    over the full width and compacted in layers not exceeding 300 mm in compacted depth. The
    et

    moisture content of material may require adjustment to that required to attain maximum
    m

    density. Material which contains insufficient moisture to obtain the desired compaction will
    require the incorporation of additional water by the use of approved sprinklers and mixing.

    3 Layers more than 300 mm below road formation levels shall be compacted to 90 % of the
    maximum dry density. Layers less than 300 mm below road formation level shall be
    compacted to 95 % of the maximum dry density. Maximum dry density shall be determined in
    accordance with CML 12-97

    4 The Contractor shall ensure that material laid immediately next to a structure, concrete wall
    or thrust block is well compacted. Hand operated vibrating plate compactors vibro-tampers
    or power rammers shall be used. In other cases, compaction shall be carried out by vibrating
    compactors smooth wheel or pneumatic tire rollers of types approved by the Engineer.

    5 In forming bunds and embankments, the Contractor shall make allowance for consolidation
    and shrinkage in attaining the dimensions of bunds and embankments shown on the
    Drawings.
    QCS 2014 Section 08: Drainage Works Page 27
    Part 02: Earthworks

    6 The Contractor shall make due allowance for consolidation and settlement of embankments
    and bunds both in width and height. Any subsidence that may occur during the period of
    maintenance shall be corrected by the Contractor at no additional cost and to the satisfaction
    of the Engineer.

    7 Round tops of cut slopes in soil to not less than a 1.8 m radius, provided such rounding does
    not extend offsite or outside easements and rights-of-way, or adversely impacts existing
    facilities, adjacent property, or completed Work.

    END OF PART

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    QCS 2014 Section 08: Drainage Works Page 1
    Part 03: Pipes and Fittings Materials

    3 PIPES AND FITTINGS MATERIALS ....................................................................... 3


    3.1 GENERAL .................................................................................................................................3
    3.1.1 Scope 3
    3.1.2 References 3
    3.1.3 System Description 5
    3.1.4 Submittals 5
    3.1.5 Delivery, Handling and Storage 6
    3.1.6 Pipe Materials 9
    3.2 VITRIFIED CLAY PIPES AND FITTINGS ..............................................................................10
    3.2.1 Standards 10
    3.2.2 Manufacture 10
    3.2.3 Inspection and Testing 11

    .
    3.2.4 Repair Couplings for VC Pipes 11

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    3.3 CONCRETE PIPES AND FITTINGS ......................................................................................11
    3.3.1 Standards 11

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    3.3.2 Pipe Materials 11
    3.3.3 Manufacture 12
    3.3.4 Plastic Lining
    ta 13
    qa
    3.3.5 Epoxy Coating 13
    3.3.6 Inspection and Testing 13
    3.4 GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS ..........................................14
    as

    3.4.1 Standards 14
    se

    3.4.2 Design 16
    3.4.3 Pipes and Fittings Manufacture 17
    er

    3.4.4 General 17
    3.4.5 Buried GRP 17
    ov

    3.4.6 Exposed GRP 23


    3.4.7 Inspection and Testing 24
    o

    3.5 PVC-U PIPES AND FITTINGS ...............................................................................................25


    it

    1.1.1 Standards 25
    et

    3.5.2 Manufacture 26
    m

    3.5.3 Joints 27
    3.5.4 Inspection and Testing 27
    3.5.5 Inspection and Testing 27
    3.6 ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS ..........................28
    3.6.1 Standards 28
    3.6.2 Manufacture 28
    3.6.3 Joints 28
    3.6.4 Inspection and Testing 28
    3.7 DUCTILE IRON PIPES AND FITTINGS .................................................................................28
    3.7.1 Standards 28
    3.7.2 Exposed Joints 28
    3.7.3 Buried Joints 29
    3.7.4 Internal Lining 29
    3.7.5 External Coating and Wrapping, Use and Materials 29
    QCS 2014 Section 08: Drainage Works Page 2
    Part 03: Pipes and Fittings Materials

    3.7.6 Factory Application of Tape Wrapping 31


    3.7.7 Factory Applied Extruded Polyethylene Coating 31
    3.7.8 Inspection and Testing 31
    3.8 FLANGE ADAPTERS AND FLEXIBLE COUPLINGS ...........................................................32
    3.8.1 General 32
    3.8.2 Flange Adapters 32
    3.8.3 Flexible Couplings 33
    3.9 PIPES FOR OTHER USE .......................................................................................................33
    3.9.1 Copper Tubes and Fittings 33
    3.9.2 Hose and Appurtenances 33
    3.9.3 Stainless Steel Pipes, Tubes and Fittings 33
    3.9.4 Carbon Steel Pipes and Fittings 34

    .
    3.10 MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES .......................................34

    l
    .l.
    3.10.1 Applicable Standards 34
    3.10.2 Manufacture 35

    rw
    3.10.3 Fittings 37
    3.10.4 Pipes and Fittings for Gravity Applications 38
    3.10.5 Testing of MDPE and HDPE Pressure Pipes and Fittings
    ta 38
    qa
    3.11 POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-PRESSURE
    DRAINAGE AND SEWERAGE ...............................................................................................41
    3.11.1 General 41
    as

    3.11.2 Resin 41
    3.11.3 Minimum strength 41
    se
    er
    ov
    it o
    et
    m
    QCS 2014 Section 08: Drainage Works Page 3
    Part 03: Pipes and Fittings Materials

    3 PIPES AND FITTINGS MATERIALS

    3.1 GENERAL

    3.1.1 Scope

    1 This Part includes the manufacture, factory testing and supply of pipes and appurtenances of
    different materials for use in pipelines.

    2 Related Sections and Parts are as follows:

    This Section
    ........................ Part 1 General
    ........................ Part 4 Pipeline Installation

    l.
    ........................ Part 5 Valves, Penstocks and Appurtenances

    .l.
    ........................ Part 6 Miscellaneous Metal Works

    rw
    ........................ Part 7 Miscellaneous GRP Works
    ........................ Part 8 Protective Coatings and Painting
    ........................ Part 11 Sewer Rehabilitation
    ........................ Part 12
    ta
    Vacuum Sewerage System
    qa
    Section 5 Concrete
    Section19 Plumbing Works
    as

    Section 20 Drainage Works to Buildings.


    3.1.2 References
    se

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


    er

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


    ov

    ANSI B16.5.................Steel Pipe Flanges and Flanged Fittings


    ANSI B16.9.................Factory-Made Wrought Steel Butt Welding Fittings
    o

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


    it

    ANSI B16.28...............Wrought Steel Butt Welding, Short Radius Elbows and Returns
    et

    ANSI B 36.19..............Stainless Steel Pipe


    m

    ASTM A53 ..................Standard specifications for Pipe, Steel, Black and Hot-dipped, Zinc-
    coated Welded and Seamless
    ASTM A105 ................Standard specifications for Forging, Carbon Steel, for Piping
    Components
    ASTM A182 ................Standard specifications for Forged or Rolled Alloy-steel Pipe Flanges,
    Forged Fittings, Valves and Parts for High Temperature Service
    ASTM A234 ................Standard specifications for Piping Fittings of Wrought Carbon Steel
    and Alloy Steel for Moderate and Elevated Temperatures
    ASTM A240 ................Standard specifications for Heat-Resisting Chromium and Chromium-
    Nickel Stainless Steel Plated, Sheet and Strip for Pressure Vessels
    ASTM A312 ................Standard specifications for Seamless and Welded Austenitic Stainless
    Steel Pipes
    QCS 2014 Section 08: Drainage Works Page 4
    Part 03: Pipes and Fittings Materials

    ASTM A403 ................Standard specifications for Wrought Austenitic Stainless Steel Piping
    Fittings
    ASTM A774 ................Standard specifications for As-Welded, Wrought Austenitic Stainless
    Steel Fittings for General Corrosive Service at Low and Moderate
    Temperature
    ASTM A778 ................Standard specifications for Welded Unannealed Austenitic Stainless
    Steel Tubular Products

    ASTM D1000 ..............Standard Test Methods for Pressure-Sensitive Adhesive-Coated


    Tapes Used for Electrical and Electronic Applications
    ASTM D1004 ..............Standard Test Method for Initial Tear Resistance of Plastic Film and
    Sheeting
    ASTM D2412 ..............Standard Test Methods for External Loading Characteristics of Plastic

    .
    Pipe by Parallel Plate Loading

    l
    .l.
    ASTM D2584 ..............Standard Test Method for Ignition Loss of Cured Reinforced Resins

    rw
    ASTM D3681 ..............Standard Test Method for Chemical Resistance of Fiberglass (Glass-
    Fiber-Reinforced Thermosetting Resin) Pipe in a Deflected Condition

    ta
    AWWA C209 ..............Cold-Applied Tape Coatings for the Exterior of Special Sections,
    qa
    Connections, and Fittings for Steel Water Pipelines
    as

    BS 65:1991.................Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for
    use solely with surface water pipes and fittings
    se

    BS 864........................Capillary and compression tube fittings of copper and copper alloy


    BS 2494......................Elastomeric seals for joints in pipework and pipelines
    er

    BS 2782......................Methods of testing plastics


    ov

    BS 3063......................Dimensions of gaskets for pipe flanges


    BS 3396......................Woven glass fibre fabrics for plastics reinforcement
    o

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


    it

    BS 3749......................E Glass fibre woven rovings for the reinforcement of polyester and
    et

    epoxy resin systems


    m

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


    BS 4346......................Joints and fittings for use with unplasticised PVC pressure pipe
    BS 5391...................... Acrylonitrile butadiene-styrene (ABS) pressure pipe
    BS 5392...................... Acrylonitrile butadiene-styrene (ABS) fittings for use with ABS
    pressure pipe.
    BS 5556......................General requirements for dimensions and pressure ratings for pipe of
    thermoplastic materials
    BS 5911......................Concrete pipes and ancillary concrete products
    BS 5955......................Code of practice for plastic pipework (thermoplastic materials)
    BS 6076......................Tubular Polyethylene film for use as protective sleeving or buried iron
    pipes and fittings
    BS EN 197..................Cement
    BS EN 295..................Vitrified clay pipes and fittings and pipe joints for drains and sewers
    QCS 2014 Section 08: Drainage Works Page 5
    Part 03: Pipes and Fittings Materials

    BS EN 545..................Ductile iron pipes, fittings, accessories and their joints for water
    pipelines - Requirements and test methods
    BS EN 598 ----------- ...Ductile iron pipes, fittings, accessories and their joints for sewer
    pipelines - Requirements and test methods
    BS EN 639..................Common requirements for concrete pressure pipes including joints
    and fittings
    BS EN 642..................Prestressed concrete pressure pipes
    BS EN 1057................Copper and copper alloys
    BS EN 1092................Flanges and their joints
    BS EN 1401................Plastic piping systems
    BS EN 12620..............Aggregates for Concrete
    BS EN 13244..............Plastic piping systems

    .
    BS EN 14020..............Reinforcements. Specification for textile glass rovings

    l
    .l.
    BS EN 14118..............Reinforcement. Specifications for textile glass mats

    rw
    BS EN 14364 & BS EN 1796 ---- Glass-reinforced thermosetting plastics (GRP)
    BS EN ISO 1456 ........Metallic and other inorganic coatings

    ta
    DIN 30674-3 ...............Coating of ductile cast iron pipes; zinc coating with protective covering
    qa
    ISO 4179 ....................Ductile Iron Pipes for Pressure and Non-Pressure Pipelines,
    as

    Centrifugal Cement Mortar Lining, General Requirements


    ISO 4633 ....................Rubber Seals - Joint Rings for Water Supply, Drainage and Sewage
    se

    Pipelines - Specification for Materials.


    er

    3.1.3 System Description


    ov

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

    2 Treated sewage effluent pipelines shall be suitable for chlorine concentration up to 15 mg/l.
    et

    3 Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting
    m

    the following characteristics unless otherwise specified:


    SO3 Content : 1.7 g/l
    Cl Content : 1.07 g/l
    pH : 8.6
    Conductivity : 4000 s/cm
    4 The Contractor's attention is drawn to the stringent limits on infiltration detailed in Clause
    4.5.2 of this section.

    5 The Contractor shall be responsible for providing a jointing system as recommended by the
    pipe manufacturer that enables the installation and use of the designated pipeline systems.

    3.1.4 Submittals

    1 The Contractor shall order materials to suit the construction programme and obtain the
    Engineers approval of submittals before placing orders. The Contractor shall submit two
    copies of the following documents for the approval of the Engineer:
    QCS 2014 Section 08: Drainage Works Page 6
    Part 03: Pipes and Fittings Materials

    (a) product data


    (i) originals of catalogues and engineering data sheets for manufactured items.
    Each item and option to be provided shall be clearly marked and each item not
    to be provided shall be deleted
    (ii) literature to show that products provided meet the requirements for material,
    construction, operation, and tests
    (iii) information on the following items as a minimum:
    pipes
    flexible couplings
    gaskets
    isolating joints

    .
    sealant systems

    l
    .l.
    linings and protective coatings

    rw
    (iv) manufacturers installation instructions for all items
    (v) certified reports for all tests and inspections designated herein, signed and

    ta
    sealed, showing full compliance with referenced standards
    qa
    (vi) maintenance requirements and procedures
    (vii) period of guarantee for products
    as

    (viii) Manufacturers test reports for hydrostatic proof testing, sustained pressure
    testing and burst strength testing.
    se

    (b) shop drawings


    er

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

    (ii) fittings, couplings, and joints


    o

    (iii) for concrete pipes, details of reinforcement, concrete and joints for straight
    it

    (iv) pipes, specials and connections


    et

    (c) design data


    m

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

    3.1.5 Delivery, Handling and Storage

    1 Each pipe, fitting and special appurtenance shall be marked with permanent identification
    which shall include but not necessarily limited to the following:

    (a) nominal diameter


    (b) name or trade mark of manufacturer
    (c) serial number
    (d) class of pipe, pressure rating in compliance with referenced standards
    QCS 2014 Section 08: Drainage Works Page 7
    Part 03: Pipes and Fittings Materials

    (e) date of manufacture


    (f) type of service
    (g) details on fittings such as angle of change and taper
    (h) circular concrete pipes with asymmetrical reinforcement shall have the letter "T" clearly
    marked on the inside and outside to indicate the top of the pipe when laid.

    2 The acceptability of the pipes and fittings on delivery to the Site will be based on the results of
    tests carried out by one or more of the following:

    (a) the manufacturer at the place of manufacturer


    (b) the Engineer
    (c) a third party on behalf of the Engineer

    .
    3 The Engineer shall be permitted at all reasonable times to visit places of manufacture to

    l
    .l.
    witness tests.

    rw
    4 The Engineer may require checking of the dimensional accuracy of GRP pipes and fittings at
    the place of manufacture, the cost of such verification shall be borne by the Contractor.

    5 ta
    Transport, handling and storage of pipes and fittings shall be carried out as follows:
    qa
    (a) in accordance with the manufacturers recommendations subject to the approval of the
    Engineer
    as

    (b) effective precautions shall be taken to prevent damage to the pipe and fittings.
    se

    6 During transport
    er

    (a) pipes and fittings shall be well secured and adequately supported along their length
    (b) bolsters and binding of approved type shall be used
    ov

    (c) nesting of pipes (placing a smaller pipe inside a larger) may be permitted for pipes of
    certain materials and size provided that methods statements demonstrate that
    o

    effective precautions will be taken to protect all pipe surfaces and coatings from
    it

    damage
    et

    (d) no pipe shall overhang the end of a vehicle


    m

    (e) pipes and fittings of plastic materials shall be covered.

    7 Handling shall be carried out as follows:

    (a) pipes should be lifted singly and not handled as bunches


    (b) pipes shall be handled only by means of
    (i) approved hooks, of the type having a plate curved to fit the curvature of the
    inside of the pipe, on ends of sections
    (ii) fabric slings not less than 250 mm wide
    (iii) other methods approved for the pipe used
    (c) use of wire rope, chains and fork lift trucks will not be permitted
    (d) for strings of pipe longer than the standard length precautions shall be taken to avoid
    curvature and longitudinal stress in excess of allowable limits
    QCS 2014 Section 08: Drainage Works Page 8
    Part 03: Pipes and Fittings Materials

    (e) pipes and fittings of plastic materials


    (i) smaller than 300 mm diameter may be handled manually, larger than 300 mm
    diameter and greater than 4 metres in length shall be lifted using fabric lifting
    straps or large diameter rope slings positioned at a quarter of the pipe length
    from each end
    (ii) there should be enough slack in the slings to keep the hook approximately
    600 mm over the pipe
    (iii) steel chain or hooks shall not come into contact with the pipe
    (f) VC pipes and fittings shall be transported in pallets and handled only with suitable
    equipment
    (g) pipes and fittings shall not be dropped or bumped
    (h) pipes shall not be dragged over the ground

    l .
    .l.
    (i) if rolled, pipes shall be rolled only over adequate timber bearers to prevent damage

    rw
    (j) where necessary, chocks shall be used to prevent lateral movement of pipes.

    8
    ta
    All pipes, fittings and materials shall be stored in accordance with the manufacturer's
    recommendations and the following:
    qa
    (a) pipes may be stored in the open on a flat level area and raised above the ground on
    timber bearers so that the lowest point of any pipe or fitting is not less than 150 mm
    as

    above the ground


    (b) timber bearers not less than 200 mm wide and 75 mm thick to be provided at 4 m
    se

    intervals maximum
    er

    (c) if on pallets or crated, on the pallets or in their crates until required


    ov

    (d) if not on pallets or not crated, stacked one above the other as follows:
    in accordance with the manufacturers recommendations but not to a greater number
    of tiers than the following:
    it o

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


    et

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


    ........................ < 600 mm diameter 4 tiers
    m

    (i) suitable protective packing shall be placed between tiers to the approval of the
    Engineer
    (ii) wrapped pipes shall not be stacked
    (e) if spigot and socket, stacked so that successive pipe layers have sockets protruding
    at opposite ends of the stack
    (f) with pipes of different sizes and thickness stacked separately
    (g) with maximum height of stacked pipes not exceeding 2 m, or that recommended by
    the supplier if less than 2 m.

    9 Pipes and fittings of plastic materials including GRP shall be:

    (a) stored under cover and out of direct sunlight


    (b) adequately supported along their length
    QCS 2014 Section 08: Drainage Works Page 9
    Part 03: Pipes and Fittings Materials

    (c) provided with a free flow of air around the pipe.

    10 Storage of jointing materials shall be as follows:

    (a) under cover


    (b) rubber ring gaskets shall
    (i) be stored in their original packing
    (ii) not be exposed to sunlight
    (iii) protected from exposure to greases and oils
    (c) gasket lubricants shall be stored so as to prevent damage to the container.

    11 Pipes and fittings shall be protected in storage to the approval of the Engineer by means of
    an impermeable membrane which shall cover the pipes and fittings and separate them from

    .
    the ground on which they are supported. The membrane shall be strong and durable in the

    l
    .l.
    prevailing climate conditions.

    rw
    12 Pipes and fittings shall be subject to visual inspections after off-loading at site and before
    installation.

    13 ta
    The following procedures shall be followed for dealing with damaged pipes and fittings:
    qa
    (a) pipes and fittings damaged during transportation handling and storage shall be set
    aside and the damage brought to the attention of the Engineer
    as

    (b) pipes or fittings that show signs of corrosion or deterioration during storage shall
    immediately be treated to arrest and prevent the corrosion or deterioration or
    se

    removed from Site, as the Engineer directs


    er

    (c) proposals for repair shall be submitted in writing for the Engineers approval
    no attempt shall be made to repair damage without the Engineers approval
    ov

    (d)
    (e) if in the Engineers opinion the nature of any damage is such that the condition of a
    pipe has been impaired and cannot be repaired the pipe concerned shall not be
    o

    incorporated in the Works


    it
    et

    (f) all rejected pipes shall be immediately removed from the Site
    m

    (g) damaged pipe shall be replaced or repaired by the Contractor at his expense and such
    repairs shall be to the approval of the Engineer
    (h) the Engineer may require that any GRP pipe or fittings found to be damaged to be
    subjected to a further hydraulic test which shall be carried out by the Contractor, at the
    Contractors expense, in accordance with the requirements of Subpart 4.5 of this
    Section.

    3.1.6 Pipe Materials

    1 For the purposes of this specification the following shall apply:

    (a) Pipes of steel, glass reinforced plastic (GRP), PVC-U and polyethylene shall be
    deemed to be flexible pipes.
    (b) Pipes of concrete, vitrified clay and ductile iron shall be deemed to be rigid pipes.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 03: Pipes and Fittings Materials

    3.2 VITRIFIED CLAY PIPES AND FITTINGS

    3.2.1 Standards

    1 Pipes and fittings for foul sewerage and surface water applications shall be manufactured to
    BS EN 295.

    2 Pipes and fittings for land drainage applications shall be manufactured to BS 65.

    3 Sealing rings shall be to BS 2494 or ISO 4633.

    3.2.2 Manufacture

    1 Pipes and fittings shall comply with the following:

    l.
    (a) pipes shall have spigot and socket type joints.

    .l.
    (b) pipes shall be glazed both internally and externally.

    rw
    (c) all pipes shall be free of cracks, blisters, broken ends and other imperfections.
    (d) vitrified clay pipes shall have the minimum strength requirements shown on Table 3.2
    ta
    qa
    Table 3.2 Minimum Strength Requirements

    Min. Crushing Strength (FN) kN/m


    as

    Nominal Bore
    (mm)
    se

    Foul / SW Land Drains


    (Non-Perforated) (Perforated)
    er

    100 28 28
    150 28 28
    ov

    200 40 28
    300 60 34
    o

    400 64 44
    it

    500 80 60
    et

    600 96 -
    m

    800 96 -
    1000 95 -

    2 Joints shall be as follows:

    (a) Pipes and fittings shall be supplied with flexible mechanical joints of the spigot and
    socket type joints.
    (b) Sealing rings shall be of elastomeric material suitable for foul sewerage and
    surfacewater drainage works, as the case maybe, conforming to BS 2494 or ISO 4633.
    (c) Acceptance of VC pipes on delivery is dependent upon the Contractor demonstrating
    that the joints are capable of meeting the water test requirement of Clause 4.5.2 of this
    Section.
    (d) Polypropylene sleeve couplings shall not be used.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 03: Pipes and Fittings Materials

    3 Fittings shall be capable of withstanding the same load as the adjacent pipes or shall be
    provided with concrete surround.

    3.2.3 Inspection and Testing

    1 Barrel impermeability, straightness, crushing strength and bending moment resistance and
    chemical resistances tests shall be carried out in accordance with BS EN 295 at the
    frequency designated for the crushing strength test.

    3.2.4 Repair Couplings for VC Pipes

    1 Repair couplings shall be obtained from an approved manufacturer and shall consist of a
    moulded synthetic elastomeric sleeve which is fastened over the pipe ends by stainless steel
    clamping bands and be complete with a stainless steel shear ring. The repair coupling shall
    be suitable for use with vitrified clay pipes and shall include a bushing adapter when joining to

    l .
    a pipe of the same nominal bore but of a different outside diameter.

    .l.
    rw
    2 Repair couplings shall comply with the joint performance requirements of BS 65 and be
    capable of withstanding an external water pressure of 60 kPa without leaking.

    3
    ta
    Sleeves and bushes shall comply with the requirements of BS EN 681-1. Clamping bands
    and shear ring shall be made from 300 series austenitic stainless steel.
    qa
    3.3 CONCRETE PIPES AND FITTINGS
    as

    3.3.1 Standards
    se

    1 Except as otherwise designated, concrete pipes and fittings shall conform to the
    er

    requirements of this Subpart following standard specifications:


    ov

    (a) reinforced and unreinforced, BS 5911


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

    2 The strength requirement and other features of particular application shall be as specified in
    it

    this Subpart or designated in the contract specific documentation.


    et

    3.3.2 Pipe Materials


    m

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

    2 Aggregate shall conform to BS 882.

    3 Reinforcement shall conform to BS 4449 or BS 4483 as appropriate.

    4 Admixture shall be used only with the written permission of the Engineer. The methods of use
    and the quantities of admixtures used shall be subject to the approval of the Engineer.
    Admixture containing calcium chloride will not be permitted.
    QCS 2014 Section 08: Drainage Works Page 12
    Part 03: Pipes and Fittings Materials

    3.3.3 Manufacture

    1 Pipes and Fittings:

    (a) Storage of concrete materials, mixing, curing and testing of concrete shall be in
    accordance with the appropriate Clauses in Section 5. Any deviation from these
    clauses shall be made only with the approval of the Engineer
    (b) unless stated otherwise crushing strengths of pipes shall not be less than those
    designated in BS 5911 for the designated classes of pipes.
    (c) Reinforced concrete pipes shall have a minimum effective length of 2.5 m except as
    otherwise designated or required for special purposes such as curves, closures or
    built in pipes.
    (d) Steel reinforcement shall be accurately placed in the concrete wall. The placement of

    .
    all steel shall not vary from the designated position in the pipe wall by more than

    l
    6 mm from the nominal position. In no case shall the cover to the reinforcement be

    .l.
    less than 25 mm.

    rw
    (e) The planes of the ends of the pipes shall be perpendicular to their longitudinal axis.

    2 Joints
    ta
    qa
    (a) except as specified in other Parts of this Section, pipe joints shall be supplied with
    flexible mechanical joints of the spigot and socket type in accordance with BS 5911,
    double collar or sleeve type
    as

    (b) gasket stock shall


    se

    (i) comply with BS 2494.


    (ii) be a synthetic rubber compound in which the elastomer is exclusively neoprene.
    er

    (iii) solid compound shall contain not less than 50 % by volume of neoprene and
    ov

    shall not contain reclaimed rubber or deleterious substances.


    (iv) stock shall be extruded or moulded and cured in such a manner that
    it o

    cross-sections are dense, homogeneous and free from porosity, blisters, pitting
    et

    and other imperfections.


    m

    (v) stock shall be extruded or moulded with smooth surfaces to the designated size
    within a tolerance of 6 % measured on joint cross-section dimensions.
    (c) the sealing ring shall be confined in a contained groove on the spigot face of each
    pipe section to properly position and confine the rubber gaskets in the annular space
    (d) each joint shall contain a neoprene ring gasket as follows:
    (i) the gasket shall be the sole element depended upon for watertightness of the
    joint.
    (ii) the gasket shall be of circular cross-section unless otherwise approved by the
    Engineer.
    (iii) the length and cross-sectional diameter of the gasket, the annular space
    QCS 2014 Section 08: Drainage Works Page 13
    Part 03: Pipes and Fittings Materials

    (iv) provided for the gasket, and all other joint details shall be such as to produce a
    watertight joint which shall not leak when pulled 13 mm over and above the
    initial jointing allowance.
    (e) the initial jointing allowance is the gap between the spigot and the shoulder of
    the socket measured parallel to the centre of the pipeline and shall not be less than
    6 mm or greater than 12 mm.
    (f) Joints shall be capable of maintaining water tightness up to an angular deflection of 2
    from true, in any direction.

    3.3.4 Plastic Lining

    1 Where designated concrete pipes shall be lined with polyvinyl chloride plastic (PVC) liner
    plate. The PVC liner plate material shall be as specified in Section 5 Part 14.6. The liner plate
    shall be securely fixed to the formwork before pouring concrete and all in-situ welding of the

    l .
    liner plate shall be carried out by skilled labour using the methods specified by the

    .l.
    manufacturer. Purpose made units shall be used where required; e.g., at junctions.

    rw
    2 The installation of liner plates in concrete pipes or structures, and the sealing and welding of
    joints, shall be carried out in strict compliance with all applicable specifications, instructions

    ta
    and recommendations of the plastic liner plate manufacturer. All welding of liner plate shall
    be carried out by properly trained and approved workmen.
    qa
    3 Once cast into the pipe, the liner shall be permanently and physically attached to the concrete
    as

    by the locking mechanism and shall not rely on an adhesive bond.

    4 The lining shall withstand a 100 kPa hydrostatic back pressure applied to the under surface
    se

    of the lining without losing anchorage or without rupture.


    er

    5 Damaged liner plate shall be repaired in accordance with the manufacturers


    ov

    recommendation and to the approval of the Engineer.

    3.3.5 Epoxy Coating


    it o

    1 All exterior surfaces of concrete pipes shall be coated by the pipe manufacturer with a heavy
    et

    duty, solvent free epoxy suitable for application to fresh concrete as specified in Section 5. A
    minimum of two coats shall be applied to attain a minimum total dry film thickness of 400 m.
    m

    3.3.6 Inspection and Testing

    1 Inspection procedures and tests shall be carried out at the place of manufacture. Pipes and
    joints shall be hydrostatically tested in accordance with BS 5911.

    2 The performance of pipes shall be verified by the testing of random sample pipes in
    accordance with the type of inspection and batch size mentioned. The pipes shall be subject
    to rejection on account of non-compliance with the following:

    (a) failure to pass hydrostatic test


    (b) failure of the longitudinal concrete surfaces of joints to meet dimensional tolerances
    (c) fractures or cracks
    (i) passing through the shell, except that a single end crack that does not exceed
    the depth of the joint shall not be cause for rejection; however
    QCS 2014 Section 08: Drainage Works Page 14
    Part 03: Pipes and Fittings Materials

    (ii) if a single end crack that does not exceed the depth of the joint exists in more
    than 10 % of the pipes inspected, the defective pipes shall be rejected
    (d) defects that indicate defective mixing and moulding
    (e) surface defects indicating honeycomb or open texture
    (f) spalls
    (i) deeper than one half the depth of the joint
    (ii) extending more than 100 mm around the circumference
    (iii) smaller than one half the depth of the joint or less than 100 mm around the
    circumference exist in more than ten percent of the pipes
    (g) insufficient cover to the reinforcement.

    .
    3.4 GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS

    l
    .l.
    rw
    3.4.1 Standards

    1 All activities relating to this section of the particular specification shall comply with the

    ta
    following or approved equal standard. The latest version of the standard indicated shall
    apply.
    qa
    Statutory provisions shall always apply as amended from time to time.
    as

    Generally applicable standards:


    BS EN 681 .................Elastomeric seals. Material requirements for pipe joint seals used in
    se

    water and drainage applications.


    BS EN 14364 .............Plastic piping systems for drainage and sewerage with or without
    er

    pressure. Glass reinforced-thermosetting plastics (GRP) based on


    unsaturated polyester resin (UP). Specification for pipes, fittings and
    ov

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

    Glass-reinforced thermosetting plastics (GRP) based on unsaturated


    it

    polyester resin (UP)


    et

    CEN TS 14632 ...........Plastics piping systems for drainage, sewerage and water supply,
    pressure and non-pressure - Glass-reinforced thermosetting plastics
    m

    (GRP) based on unsaturated polyester resin (UP) - Guidance for the


    assessment of conformity
    ISO 25780 ..................Plastic piping systems for pressure and non-pressure water supply,
    irrigation, drainage or sewerage Glass-reinforced thermosetting
    plastics (GRP) systems based on unsaturated polyester (UP) resin
    Pipes with flexible joints intended to be installed using jacking
    techniques
    ISO 3126 ...................Plastic pipes. Measurement of dimensions wall thickness table.
    ISO 4633 ...................Joint rings for water supply, drainage and sewerage pipelines:
    Specification for materials
    ISO 1172 ....................Textile-glass-reinforced plastics, prepregs, moulding compounds and
    laminates - Determination of the textile-glass and mineral-filler content
    - Calcination methods
    DIN 16 869 - Part 1 ...Centrifugally cast and filled glass fibre reinforced polyester resin pipes
    - dimensions.
    QCS 2014 Section 08: Drainage Works Page 15
    Part 03: Pipes and Fittings Materials

    DIN 16 869 - Part 2 ...Glass-fibre reinforced polyester resin pipes (UP-GF) Centrifugally
    cast filled Part 2: General quality requirements, testing.
    DIN EN ISO 178 ........Plastics Determination of flexural properties (ISO 178:1993)
    DIN EN ISO 527-1 .....Plastics Determination of tensile properties Part 1: General
    principles
    DIN EN ISO 527-2 .....Plastics - Determination of tensile properties - Part 2: Test conditions
    for moulding and extrusion plastics
    ISO 15306 ..................Glass-reinforced thermosetting plastics (GRP) pipes Determination
    of the resistance to cyclic internal pressure
    ISO 10952 .................Plastics piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes and fittings Determination of the resistance to
    chemical attack for the inside of a section in a deflected condition
    ISO 10928 ..................Plastics piping systems - Glass-reinforced thermosetting plastics

    .
    (GRP) pipes and fittings - Methods for regression analysis and their

    l
    .l.
    use

    rw
    DIN 16966 -6 ..............Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint
    assemblies; collars, flanges, joint rings, dimensions
    DIN-16945 .................Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins

    ta
    DIN-16946 - Part 1 ....Cured casting Resins - Testing DIN-16946- Part 2 Cured casting
    qa
    Resins - Types
    DIN EN ISO 75 ..........Plastics Determination of temperature of deflection under load
    as

    DIN EN ISO 527-4 .....Plastics Determination of tensile properties Part 4: Test conditions
    for isotropic and orthotropic fibre-reinforced plastic composites
    se

    DIN EN ISO 10468 ....Glass-reinforced thermosetting plastics (GRP) pipes Determination


    of the long-term specific ring creep stiffness under wet conditions and
    er

    calculation of the wet creep factor (ISO/DIS 10468:1999)


    DIN EN ISO 14828 ....Glass-reinforced thermosetting plastics (GRP) pipes Determination
    ov

    of the long-term specific ring relaxation stiffness under wet conditions


    and calculation of the wet relaxation factor (ISO/DIS 14828:1999)
    o

    DIN EN 681-1 ............Elastomeric seals Material requirements for pipe joint seals used in
    it

    water and drainage applications Part 1: Vulcanized rubber


    et

    DIN EN 1119 .............Plastics piping systems Joints for glass-reinforced thermosetting


    plastics (GRP) pipes and fittings Test methods for leak tightness and
    m

    resistance to damage of flexible and reduced articulation joints


    ISO 10466 .................Plastics piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes Test method to prove the resistance to initial ring
    deflection
    ISO 7685 .................... Plastics piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes Determination of initial specific ring stiffness
    ISO 8513 ....................Plastics piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes Determination of longitudinal tensile properties
    ISO 8521 ....................Plastic piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes Test methods for the determination of the apparent
    initial circumferential tensile strength
    DIN EN 1447 .............Plastics piping systems Glass-reinforced thermosetting plastics
    (GRP) pipes Determination of long-term resistance to internal
    pressure
    QCS 2014 Section 08: Drainage Works Page 16
    Part 03: Pipes and Fittings Materials

    ISO 7509 ....................Plastics piping systems Glass-reinforced thermosetting plastics


    (GRP) pipes Determination of time to failure under sustained
    internal pressure
    ASTM D2997 .............Standard Specification for Centrifugally cast Fiberglass (Glass-Fiber-
    Reinforced Thermosetting-Resin) Pipe.
    EN ISO 2078 ..............Textile glass Yarns Designation (ISO 2078)
    ASTM D 3517-01 .......Standard Specification for Fiberglass(Glass-Fiber-Reinforced
    Thermosetting-Resin) Pressure Pipe

    3.4.2 Design

    1 The design of GRP pipes, fittings and bedding shall be carried out by the pipe manufacturer
    to enable the pipe to meet the requirements of the Works. The following general
    requirements shall prevail for pipes and fittings:

    l .
    .l.
    (a) they shall be designed to achieve a minimum working life of 60 years under all
    applicable standard loadings, environmental and installation conditions

    rw
    2
    (b) they shall have a minimum stiffness of 10,000 N/m
    (c) Non-pressure pipes and fittings shall be designed for a nominal pressure rating of PN
    01 (1 bar)
    ta
    qa
    (d) Pressure pipes and fittings shall be designed for a normal operating pressure rating of
    PN16 (16 bar) to pressure ratings in ISO 25780, EN 14364 or EN 1796.
    as

    (e) they shall convey a liquid with a temperature up to 45C


    (f) they shall be designed to withstand up to 5% long term deflection in their installed
    se

    conditions.
    er

    (g) all bends shall be long radius bends unless otherwise approved by the Engineer.
    ov

    (h) they shall be capable of withstanding a 95% lower confidence strain of 0.85% over 60
    years without failure or cracking when tested in accordance with the strain corrosion
    type test requirements specified herein.
    o

    (i) sewerage and drainage pipelines and fittings shall be designed to carry septic sewage
    it

    having a maximum hydrogen sulphide concentration of 50mg/l at a temperature of


    et

    45C
    m

    (j) irrigation pipelines and fittings shall conform to the water supply standards
    (k) The manufacturer shall provide a valid Certificate of Conformity to EN 1796, EN 14364
    or ISO 25780 as applicable. The certificate shall be issued by an independent
    certification body or authority.
    (l) For direct jack GRP pipes, the allowable jacking force shall be based on the minimum
    wall thickness measured at the bottom of the spigot gasket groove where the wall
    cross section has been reduced, and the mean longitudinal compressive strength of
    the pipe. A minimum factor of safety of 3.5 in accordance with ISO 25780 shall be
    used for the jacking force on a straight alignment. A reduced jacking force shall be
    used when jacking to a curvature.
    (m) Direct jack GRP pipes can be used for pressure and non-pressure applications.
    QCS 2014 Section 08: Drainage Works Page 17
    Part 03: Pipes and Fittings Materials

    3.4.3 Pipes and Fittings Manufacture

    1 The pipes and fitting shall conform to either EN 14364 or EN 1796 for sewage or water
    supply pipes. Jacking pipes shall comply with ISO 25780. The referenced test standards
    therein have to be fulfilled.

    3.4.4 General

    1 All GRP components shall be designed and fabricated by one manufacturer.

    2 GRP pipes and fittings shall be manufactured by an approved process utilising a mandrel or
    rotating mould incorporating equipment to accurately control the quantities and placement of
    all resins, glass and aggregates.

    3 Use resins, reinforcement and aggregates to produce pipes and fittings, which when

    l .
    combined as a composite structure will satisfy the performance requirements of this section

    .l.
    of the specification.

    rw
    4 Internal and external surfaces shall be free from irregularities, which would impair the ability
    of the component to conform to the requirements of EN 14364, EN 1796 or ISO 25780.

    3.4.5 Buried GRP ta


    qa
    1 The pipes and fittings shall be constructed using chopped and /or continuous glass filaments,
    as

    strands or roving, mats, synthetic veils or fabric, and polyester / vinyl ester resin, aggregate
    and fillers. If applicable, additives necessary to impart specific properties to the resin may be
    se

    used, subject to the approval of the Engineer.

    2 Filament Wound (FW) GRP Pipes and Fittings


    er

    (a) Resins
    ov

    Vinyl ester shall be used in the internal resin rich liner of the pipes and fittings.
    Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
    o

    Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
    it

    Resins shall be cured to achieve a minimum of 90% of the manufacturers


    et

    recommended Barcol hardness value.


    m

    (b) Additives
    The use of additives such as fire retardants, UV inhibitors or coloured pigments or
    dyes shall only be used for specific project based applications and their use shall be
    subject to the approval of the Engineer.
    (c) Glass reinforcement
    The glass used for the manufacture of the reinforcement shall be type E (alumina-
    calcosilicate glass), type C (alkali-calcium glass) or type ECR (alumina-borosilicate
    glass).
    The reinforcement shall be made from continuous drawn filaments of glass and shall
    have a surface treatment compatible with the resin to be used. It may be used in any
    form, e.g. as continuous or chopped filaments, strands or rovings, mat or fabric.
    (d) Aggregates
    Aggregates shall be clean, graded silica sand containing no impurities and a maximum
    moisture content of 2%. The maximum particles size of the sand aggregate shall not
    exceed 0.8mm.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 03: Pipes and Fittings Materials

    The overall sand content of the pressure pipes and fittings shall not exceed 30% by
    weight.
    The overall sand content of the non-pressure pipes and fittings shall not exceed 60%
    by weight.
    (e) Fillers
    Fillers (other than silica sand aggregate) shall only be permitted if required for a
    particular project application and be subject to the approval of the Engineer following
    satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
    hours.
    (f) Wall construction
    Lining Layer
    (i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
    layer suitably reinforced with C glass veil with a glass content not exceeding

    l .
    10% by weight. The remainder of the lining shall consist of layers of vinyl ester

    .l.
    resin and powder bound ECR acid resistant glass chopped strand mat or roving,

    rw
    depending on the method of manufacture, with a glass content of between 25%
    and 35% by weight.
    (ii)
    ta
    Sand aggregate shall not be used in the lining layer.
    qa
    Structural Layer
    (iii) The structural layer shall comprise Type E or ECR glass reinforcement and a
    thermosetting isophthalic polyester resin with or without sand aggregate.
    as

    (iv) The layer shall be built up in layers of Type E or ECR acid resistant glass chop
    se

    roving or continuous roving.


    (v) The manufacturing process shall ensure that no aggregate becomes embedded
    er

    in the internal resin rich liner layer.


    ov

    Outer Layer
    (vi) Pipes shall be provided with a resin rich layer with C glass veil reinforcement.
    o

    (vii) The resin used in the outer layer shall have a Glass Transition temperature of at
    it

    least 75C.
    et

    (viii) The use of special finishes is permitted when the pipe or fitting is expected to be
    m

    exposed to extreme climatic, environmental or ground conditions. These may


    include the provision of a sand layer, pigments or inhibitors for UV protection or
    fire retardation, subject to the approval of the Engineer.
    (g) Bends and Fittings
    Bends and fittings shall be equal or superior in quality and performance to the
    corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
    have been hydraulically tested successfully.

    3 Centrifugally Cast (CC) GRP Pipes and Fittings

    (a) Resins
    Vinyl ester shall be used in the internal pure resin liner of the pipes and fittings.
    Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
    Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
    Resins shall be cured to achieve a minimum of 90% of the manufacturers
    recommended Barcol hardness value.
    QCS 2014 Section 08: Drainage Works Page 19
    Part 03: Pipes and Fittings Materials

    (b) Additives
    The use of additives such as fire retardants, UV inhibitors or coloured pigments or
    dyes shall only be used for specific project based applications and their use shall be
    subject to the approval of the Engineer.
    (c) Glass reinforcement
    The glass used for the manufacture of the reinforcement shall be Type E or ECR
    glass.
    The reinforcement shall be made from chopped glass filament in long and short fibres
    and shall have a surface treatment compatible with the resin to be used.
    (d) Aggregates
    Aggregates shall be clean, graded silica sand containing no impurities and a maximum
    moisture content of 2%. The maximum particles size of the sand aggregate shall not
    exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.

    l .
    .l.
    (e) Fillers
    Fillers (other than silica sand aggregate) shall only be permitted if required for a

    rw
    particular project application and be subject to the approval of the Engineer following
    satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
    hours.
    (f) Wall construction ta
    qa
    Lining Layer
    (i) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
    as

    resin without glass reinforcement and sand aggregates.


    se

    (ii) The barrier and transition layers between the pure resin lining layer and the
    structural layer shall be to suit the manufacturing process.
    er

    Structural Layer
    ov

    (iii) The structural layer shall comprise glass reinforcement and a thermosetting
    isophthalic polyester or vinyl ester resin with or without sand aggregate.
    o

    (iv) The layer shall be built up in layers of ECR acid resistant glass chopped fibres.
    it

    (v) The manufacturing process shall ensure that no aggregate becomes embedded
    et

    in the inner pure resin liner layer.


    m

    Outer Layer
    (vi) Pipes shall be provided with an outer layer formed of a mortar of resin and sand
    aggregates with no glass reinforcement.
    (vii) The resin used in the outer layer shall have a Glass Transition temperature of at
    least 75C.
    (viii) An outer protection layer shall be provided which has a minimum of 60% sand
    for corrosion protection.
    (ix) The use of special finishes is permitted when the pipe or fitting is expected to be
    exposed to extreme climatic, environmental or ground conditions. These may
    include the provision of a sand layer, pigments or inhibitors for UV protection or
    fire retardation, subject to the approval of the Engineer.
    (x) The transition layers between the structural layer and the outer layer shall be to
    suit the manufacturing process.
    QCS 2014 Section 08: Drainage Works Page 20
    Part 03: Pipes and Fittings Materials

    (g) Bends and Fittings


    Bends and fittings shall be equal or superior in quality and performance to the
    corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
    have been successfully pressure tested.

    4 Direct Jack GRP Pipes

    (a) Resins
    Vinyl ester resin shall be used in the internal pure resin liner of the pipes. Isophthalic
    or vinyl ester resin shall be used in the structural layer of the pipes. Vinyl ester or
    isophthalic resin shall be used in the outer layer of the pipes.
    Resins shall be cured to achieve a minimum of 90% of the manufacturers
    recommended Barcol hardness value.
    (b) Additives

    l .
    .l.
    The use of additives such as fire retardants, UV inhibitors or coloured pigments or
    dyes shall only be used for specific project based applications and their use shall be

    rw
    subject to the approval of the Engineer.
    (c) Glass reinforcement

    ta
    The glass used for the manufacture of the reinforcement shall be Type E or ECR acid
    qa
    resistant glass.
    The reinforcement shall be made from chopped glass filament in long and short fibres
    as

    and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric
    and shall have a surface treatment compatible with the resin to be used.
    se

    (d) Aggregates
    er

    Aggregates shall be clean, graded silica sand containing no impurities and a maximum
    moisture content of 2%. The maximum particles size of the sand aggregate shall not
    ov

    exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
    (e) Fillers
    o

    Fillers (other than silica sand aggregate) shall only be permitted if required for a
    it

    particular project application and be subject to the approval of the Engineer following
    et

    satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
    m

    hours.
    (f) Wall construction
    Lining Layer
    (i) The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
    layer suitably reinforced with C glass veil with a glass content not exceeding
    10% by weight. The remainder of the lining shall consist of layers of vinyl ester
    resin and powder bound ECR acid resistant glass chopped strand mat or roving,
    depending on the method of manufacture, with a glass content of between 25%
    and 35% by weight, when the filament wound manufacturing process is used.
    (ii) The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
    resin without glass reinforcement and sand aggregates when the centrifugal
    manufacturing process is used.
    (iii) The barrier and transition layers between the pure resin lining layer and the
    structural layer shall be to suit the manufacturing process.
    QCS 2014 Section 08: Drainage Works Page 21
    Part 03: Pipes and Fittings Materials

    Structural Layer
    (iv) The structural layer shall comprise glass reinforcement and a thermosetting
    isophthalic polyester or vinyl ester resin with or without sand aggregate.
    (v) The layer shall be built up in layers of Type E or ECR acid resistant glass
    chopped fibres.
    (vi) The manufacturing process shall ensure that no aggregate becomes embedded
    in the inner pure resin liner layer.
    Outer Layer
    (vii) Pipes shall be provided with an outer layer formed of a mortar of resin and sand
    aggregates with no glass reinforcement.
    (viii) The resin used in the outer layer shall have a Glass Transition temperature of at
    least 75C.

    l .
    .l.
    (ix) An outer protection layer shall be provided which has a minimum of 60% of sand
    for corrosion protection.

    rw
    (x) The use of special finishes is permitted when the pipe is expected to be
    exposed to extreme climatic, environmental or ground conditions. These may

    ta
    include the provision of a sand layer, pigments or inhibitors for UV protection or
    qa
    fire retardation, subject to the approval of the Engineer.
    (xi) The transition layers between the structural layer and the outer layer shall be to
    suit the manufacturing process.
    as

    (xii) The outer surface of the pipes shall be smooth with a resin rich topcoat 0.3mm
    se

    thick.
    (g) Longitudinal Compressive Strength
    er

    Proof of compression strength shall be supplied by testing all pipe types using the
    ov

    procedure set out in Annex A of ISO 25780.


    The test results of compressive properties obtained from coupon or spool test
    o

    specimens may be used. As described in ISO 25780, the manufacturer shall show the
    it

    correlation of the results obtained from coupons or full spools by means of initial type
    et

    tests. The pipes shall meet the following requirements for the initial longitudinal
    compression properties:
    m

    Table 3.4.1 : Longitudinal compressive strength for direct jack GRP pipes
    Mean
    Minimum compressive
    Specimen Pipe quality compressive
    strength (single value)
    strength

    Rebated and grooved with filler 80 MPa 90 MPa


    specimen

    Coupon specimen with filler 90 MPa 100 MPa

    Rebated and grooved without filler 70 MPa 80 MPa


    specimen

    Coupon specimen without filler 80 MPa 90 MPa


    QCS 2014 Section 08: Drainage Works Page 22
    Part 03: Pipes and Fittings Materials

    (h) Dimensions
    The manufacturer shall confirm that the outside diameter of the pipe conforms to ISO
    25780.
    The outside diameter of the jacking pipe shall be compatible with the jacking machine.
    The nominal length of the pipe shall preferably be 1m, 1.5m, 2m, 3m or 6m. Other
    lengths shall be permitted to suit a particular project requirement.
    The jacking force shall be transmitted face to face on the pipe joint without the use of
    packer rings, unless required for a specific project application. The permitted deviation
    from squareness across the joints external diameter shall be as tabled below:
    Table 3.4.2 : Permissible deviation from squareness across a joints external diameter

    Manufacturers declared outside Deviation of


    diameter dOD mm squareness mm

    l.
    .l.
    dOD 300 0.5

    rw
    300 < dOD 1.0

    ta
    qa
    (i) Marking of jacking pipes
    Markings shall meet the requirements for the application and conform to ISO 25780.
    as

    Designations to meet special quality requirements as item 6 below are permissible.


    The marking of the pipe shall be visible on the external and internal surfaces of the
    se

    jacking pipe.

    5 Wall thickness
    er

    The minimum total wall thickness, including the liner and outer protective layer shall be
    ov

    declared by the manufacturer, which shall be complying with the standard performance
    criteria.
    it o

    The wall thickness at any point on the pipe and the spigot shall not be less than the
    manufacturers declared values.
    et
    m

    6 Abrasion resistance

    The pipes shall be resistant to abrasion when tested according to CEN TR 15729 over
    100,000 cycles. There shall be no evidence of free glass fibres on the inner surface of the
    pipe.

    7 Markings

    All pipes including cut lengths and all fittings before dispatch from the pipe manufacturers
    works shall be indelibly marked as follows on the external and internal surfaces.

    (a) The manufacturer's name, initials, or identification mark.


    (b) The nominal internal diameter in millimetres.
    (c) The length in metres.
    (d) The classification i.e. pressure rating, stiffness.
    QCS 2014 Section 08: Drainage Works Page 23
    Part 03: Pipes and Fittings Materials

    (e) The date of manufacture and batch number.


    (f) A stamp to show that they meet the required inspection requirements and hydraulic
    tests at the point of manufacturer.
    (g) Identification number stencilled on the inside and outside at each end. The same
    number shall appear on all record sheets and documents relating to the manufacture
    delivery and testing of that pipe.
    (h) The manufacturing standard.
    (i) The project or contract number.

    8 Joints

    Except where otherwise detailed on the Drawings, all buried pipes and fittings shall have non-
    end-load-bearing flexible joints of spigot type or GRP sleeved couplers with EPDM rubber in

    .
    full faced elements or rings in accordance with BS / DIN EN 681; manufactured according to

    l
    .l.
    the individual manufacturing technique and supplied as an integral part of the pipe or as

    rw
    separate fittings. The elastomeric sealing gaskets shall provide the sole means of
    maintaining joint watertightness. The sealing gaskets shall be supplied by the pipe
    manufacturer.

    ta
    Joints in direct jack applications (non-pressure application) can also be of stainless steel
    qa
    Grade 316 Ti (EN 1.4571) couplers with approximately the same outside diameter as the
    pipe so that the joints are essentially flush with the pipe outer surface.
    as

    The manufacturer shall declare the maximum draw for which each flexible joint type is
    designed.
    se

    The manufacturer shall declare the maximum allowable angular deflection and the maximum
    er

    draw for which each locked joint type and flexible joint type are designed.
    ov

    All joints shall remain watertight for all combinations of angular deflection and draw up to the
    maximum allowable values. In addition, pipe joints for pipelines laid in open cut trenches
    o

    shall be capable of withstanding an external pressure differential equivalent to +10m head of


    it

    water without leakage in the straight, deflected and drawn positions.


    et

    When a pipe is cut or turned down in order to form a joint, the exposed faces shall be fully
    m

    sealed with a continuous coating of vinyl ester resin with a minimum of 1.5mm thick.

    Wrapped or cemented joints shall only be used subject to the approval of the Engineer.

    3.4.6 Exposed GRP

    The use of GRP pipes and fittings for exposed service shall be subject to the approval of the
    Engineer. The exposed pipes and fittings shall be designed to resist all bending stresses,
    thrust forces, surge pressures, negative pressures, thermal and vibratory forces.

    1 Exposed pipe and fittings shall be manufactured in the same manner and with the same
    materials as buried pipe, along with the following requirements unless otherwise approved by
    the Engineer.
    QCS 2014 Section 08: Drainage Works Page 24
    Part 03: Pipes and Fittings Materials

    (a) An outer protective surface layer shall be provided consisting of a topcoat of UV


    inhibitor and resin with or without glass reinforcement to form a resin rich layer with a
    minimum thickness of 0.3mm. The outer protective surface layer shall be designed to
    resist other project specific extraneous causes (atmospheric conditions, mechanical
    damage and chemical stress etc.) as described in the project specification.

    2 Exposed pipes and fittings inside treatment plant buildings, process structures, pumping
    stations, and valve chambers shall use PN 16 flanged joints:

    (a) Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed
    with epoxy or vinyl ester resins only.
    (b) All bolts shall be stainless steel grade 316.
    (c) Flanges shall be drilled to BS EN 1092 (metric units) resp. DIN 16966-1 type PN16.
    (d) Flanged pipe joints shall incorporate an annular gasket covering the full face of the

    l .
    flange. Gaskets to be 3mm thick self-energised EPDM or nitrile rubber (NBR) with

    .l.
    embedded stainless steel inlay O rings. The gaskets shall have a shore hardness of

    rw
    605.
    (e) When flanged joints are to be made, secure the bolts and the nuts initially to finger

    ta
    tightness. Thereafter the final tightening of the nuts shall be effected by torque
    spanners in such sequence that diametrically opposite nuts are tightened together to
    qa
    achieve the manufacturers recommended torque.

    3 External exposed pipes and fittings shall use fixed laminated joints with expansion bellows
    as

    and be supported in accordance with the manufacturers requirements.


    se

    4 The exposed pipeline shall be protected by bollards, lateral sand bunds etc. where there is a
    risk of physical impact.
    er

    3.4.7 Inspection and Testing


    ov

    1 A pipe type test group consists of a range or family of products made such that the results of
    the long-term type tests are applicable to all products in the group. A pipe type test group
    o

    shall be made of products:


    it

    a) manufactured by the same process;


    et

    b) with the same material specifications;


    m

    c) with the same pipe wall construction (i.e. the sequence of layers, layer
    compositions, material properties and design method for using the results of the
    long-term type tests in determining the pipe wall for all combinations of DN, PN
    and SN);
    d) tested with the same loading condition (i.e. uniaxial or biaxial load).
    2 The pipe manufacturer shall submit type test results according to EN 14364 or ISO 25780 for
    each product group.
    3 Strain corrosion tests shall be carried for each class and diameter range, where applicable,
    according to ISO 25780 and ISO 10467, as a type test generally in accordance with ASTM
    D3262 resp. ISO 10952. The strains shall be at levels at which failure can be predicted from
    the strain corrosion type test results to occur at 100 hours and 1,000 hours. No failures shall
    be below the lower 95% confidence limit of the type test regression line.
    4 The calculated failure strain at 60 years from the results of the quality control test using the
    least squares method shall not be less than 0.85%. In the event that a specimen fails the
    strain corrosion test all pipes in that class and diameter range, where applicable, pertaining to
    that batch which has been manufactured or installed shall be rejected.
    QCS 2014 Section 08: Drainage Works Page 25
    Part 03: Pipes and Fittings Materials

    5 The pipe manufacturer shall carry out the following Inspection Tests. The results of these
    tests shall be made available to the Engineer who shall also be allowed to witness some or
    all of the tests.
    (a) One pipe in every 100 of each type and size of manufactured item shall be tested for
    loss of ignition in accordance with ASTM D2584 resp. ISO 1172.
    (b) The liner thickness of pipes, fittings and couplings shall be measured in accordance with
    Section 6 of ASTM D3567 resp EN 3126. A liner check shall be carried out for one in
    every 100 of each type and size of manufactured item. A minimum of one item of each
    type and size shall be tested. The liner thickness shall not be less than 1mm at any
    pitted point.
    (c) Data for the above tests shall be submitted to the Engineer. The data shall be traceable
    to the supplied pipes with a unique number as "Batch no", the test data shall hold all the
    above mentioned tests samples results under this batch no. The batch no. shall be
    clearly marked as ID on each length of produced pipes.

    .
    6 Checks will be carried out by the Engineer at Site. The Contractor shall destroy or indelibly

    l
    mark as rejected and remove from Site any pipes or fittings found at any time failing to meet

    .l.
    dimensional criteria or any of the following quality criteria:

    rw
    (a) scratches shall be no deeper than 0.3 mm and no reinforcing fibres shall be exposed
    (b) no cracks shall be present on the inside of pipes. Hair cracks on the outside may be

    ta
    permitted with repair if not longer than 200 mm circumferentially or 6 mm longitudinally.
    Impact cracks shall not affect more than 3 % of surface area
    qa
    (c) no delaminations shall be evident
    (d) no impact or other damage to pipe ends shall be evident. The end surface of pipe or
    as

    fitting shall be completely covered with resin and free from cracks, porosity, bubbles,
    voids, exposed reinforcement or extraneous matter
    se

    (e) no protruding fibres permitted on jointing surfaces


    (f) no other protuberances. Small globules or resin projections permissible if not more than
    er

    25 % of area is affected. Jointing surfaces shall be completely free of any such flaws.
    Ridges formed by resin shall not exceed 1.5 mm in depth
    ov

    (g) air voids, blisters, bubbles are not acceptable if greater than 5 mm diameter or 1 mm
    depth. Subject to the approval of the Engineer, if less than 0.5% of internal areas are
    o

    affected, such defects may be ground out and repaired


    it

    (h) not more than 5 % of the internal or 10 % of the external surface shall be affected by
    et

    pitting. No individual pit shall be more than 1 mm diameter or 0.5mm depth


    m

    (i) wrinkles and indentations shall not be more than 2mm deep and not more than 3 % of
    surface area affected. Subject to the approval of the Engineer, if not more than 5 mm
    deep and 0.5 percent of surface area is affected, such defects may be repaired
    (j) any pipe which when resting freely on the ground and not subjected to any loads other
    than its own weight exhibits a deflection of more than 2%, measured along the diameter,
    shall be rejected and removed from the Site.

    3.5 PVC-U PIPES AND FITTINGS

    1.1.1 Standards

    1 Except as otherwise indicated, materials and workmanship described in this section shall
    conform to the latest editions of the following standards:
    ASTM D1599 ..............Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe,
    Tubing and Fittings
    QCS 2014 Section 08: Drainage Works Page 26
    Part 03: Pipes and Fittings Materials

    AWWA M23 PVC Pipe - Design and Installation

    BS 3505/3506 - Polyvinyl Chloride Pressure Pipe

    BS EN 1401 - Plastic piping for non-pressurised underground drainage & sewerage


    BS EN 1452................Plastic piping systems for water supply (UPVC)

    DIN 8061 ....................Unplasticised polyvinyl chloride pipes - general quality requirements &
    testing
    DIN 8062: 1988 ..........Unplasticised polyvinyl chloride (PVC-U, PVC-HI) pipes dimensions
    DIN 8063: 1986 ..........Pipe joint assemblies & fittings for unplasticised polyvinyl chloride
    (PVC-U) pressure pipelines

    l .
    .l.
    ISO 1452 ....................Pipes and fittings in PVC U pipes for water supply

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

    3.5.2 Manufacture ta
    qa
    1 UPVC pipe shall be provided in standard 6 metre lengths, unless otherwise specified,
    detailed or required on the approved plans. Shorter lengths, up to 3 metres, will be permitted
    as

    when authorised by the Engineer. Field cut lengths of pipe used as closures may not be
    shorter than 0.75 metre in length and must be approved by the Engineer. Solvent welded
    se

    pipes may be permitted in sizes of 100mm and less.


    er

    2 For sewerage service, PVC-U pipes 200 mm in diameter may be supplied in lengths up to
    4 m. PVC-U pipes 150 mm in diameter and less shall be supplied 50 percent in lengths not
    ov

    exceeding 2 m and 50 percent in lengths not exceeding 4 m.


    o

    3 UPVC Pipes shall be SDR17 as a maximum and shall have be designed to withstand a
    0 0
    it

    nominal operating pressure of PN16 at 25 C (equivalent to PN10 at 45 C) unless otherwise


    et

    specified in the Contract Documents.


    m

    4 All joints for UPVC Pressure Pipe shall be integrally cast, spigot and socket joints, or plain
    end with EPDM rubber ring couplings. Joints shall be of the same pressure rating as the pipe.
    Solvent weld joints are not permitted for TSE Mains. Gaskets and lubricants shall be made
    from materials that are compatible with the plastic material and with each other when used
    together. They shall not support the growth of bacteria and shall not adversely affect the
    potable qualities of the water that is to be transported. One elastomeric gasket shall be
    furnished with each length of socket-end pipe.

    5 Pipe shall have a minimum internal diameter equal to or greater than the pipe size shown on
    the Drawings and Bills of Quantities. SDR shall be defined as outside diameter divided by
    wall thickness. Acceptable PVC pipe shall have common profiles for interchangeability
    between rough barrel dimensions, couplings, ends and elastomeric gaskets so as to facilitate
    future repairs. When assembled, the pipe shall have only one gasket per socket and spigot
    end.
    QCS 2014 Section 08: Drainage Works Page 27
    Part 03: Pipes and Fittings Materials

    6 Pipes delivered to site shall be no more than 12 months old. The Engineer reserves the right
    to reject the pipes older than 12 months old.

    3.5.3 Joints

    1 Solvent welded joints shall not be permitted for sewerage pipelines and all jointing shall be by
    socket and spigots with sealing rings which shall conform to BS 2494.

    2 Unless otherwise designated, irrigation pipework up to 100 mm in diameter shall be solvent


    welded in accordance with BS 4346 Part 1.

    3.5.4 Inspection and Testing

    1 Inspection and testing for sewer pipes shall be in accordance with an approved inspection
    and test plan.

    l .
    .l.
    2 Inspection and testing for irrigation pipes shall be in accordance with an approved inspection

    rw
    and test plan.

    3 Test certificates shall be provided by the manufacturer.

    4 ta
    All pipes may be subject to inspection at the place of manufacture in accordance with the
    qa
    provisions of the referenced standards as supplemented by the requirements herein. The
    Contractor shall notify the Engineer in writing of the manufacturing starting date not less than
    as

    14 calendar days prior to the start of any phase of the pipe manufacture.

    5 During the manufacture of the pipe, the Engineer shall be given access to all areas where
    se

    manufacturing is in process and shall be permitted to make all inspections necessary to


    confirm compliance with the Specifications.
    er
    ov

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

    convenience of the Engineer.


    it
    et

    7 In addition to those tests specifically required, the Engineer may request additional samples
    of any material for testing by the Engineer.
    m

    8 All expenses incurred in obtaining samples for testing shall be borne by the Contractor at no
    additional cost to the Contract.

    3.5.5 Inspection and Testing

    1 All fittings shall be push-on joint with mechanical fittings. Fittings shall be in uPVC material
    compatible with the above specified pipe and having the same minimum Class and Pressure
    Rating. The fittings when connected to the main pipe shall provide an integral system
    capable of withstanding the working and test pressure.
    QCS 2014 Section 08: Drainage Works Page 28
    Part 03: Pipes and Fittings Materials

    3.6 ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS

    3.6.1 Standards

    1 Acrylonitrile butadiene-styrene (ABS) pipes and fittings for pressure pipes shall conform to
    BS 5391 and BS 5392.

    3.6.2 Manufacture

    1 Unless otherwise designated, ABS pipes and fittings shall be class E and manufactured in
    accordance with BS 5391 and BS 5392.

    3.6.3 Joints

    1 ABS pipes shall be provided with socket and spigot joints, sealed with elastomeric sealing

    .
    l
    rings conforming to BS 2494.

    .l.
    rw
    3.6.4 Inspection and Testing

    1 Inspection and testing for pipes and fittings shall be in accordance with BS 5391 and
    BS 5392.
    ta
    qa
    3.7 DUCTILE IRON PIPES AND FITTINGS
    as

    3.7.1 Standards
    se

    1 Unless otherwise stated in the Contract Documents ductile iron pipes and fittings for pipes
    shall comply with BS EN 545 and shall be suitable for an allowable operating pressure (PFA)
    er

    of 16 Bar and an allowable maximum operating pressure (PMA) of 20 bar.


    ov

    2 Unless otherwise stated in the Contract Documents, flanges on ductile iron pipework and
    fittings shall comply with BS EN 1092-2 and shall be PN16.
    o

    3 All puddle flanges shall be cast integrally with the wall piece.
    it
    et

    3.7.2 Exposed Joints


    m

    1 Ductile iron flanged pipes shall be furnished with integrally cast flanges or screwed on flanges
    faced and drilled to class designation. Steel bolts and nuts shall be supplied with two
    washers per bolt. Bolt length shall be such that after the joints are made up, the bolts shall
    protrude through the nut, but not more than 12 mm. Bolts shall be stainless steel grade to
    BS 970 Grade 316 S31.

    2 Gaskets shall be compatible with the fluid to be conveyed. For treated sewage effluent
    pipelines, EPDM gaskets shall be used. Gaskets shall be able to withstand a pressure of
    PN 16 for a 24 h test period. Thickness of gaskets shall be such that, when jointed in
    accordance with manufacturers instructions, the joint shall provide a positive seal for the
    range of pressures likely to occur in the pipeline under the maximum joint deflection
    permitted.

    3 Pipes and fittings in chambers and pumping stations shall have flanged joints unless detailed
    otherwise. Flanges shall comply with BS EN 1092-2 and shall be PN16 unless a higher
    pressure rating is detailed elsewhere.
    QCS 2014 Section 08: Drainage Works Page 29
    Part 03: Pipes and Fittings Materials

    3.7.3 Buried Joints

    1 Pipes and fittings to be buried shall have flexible joints unless detailed otherwise.

    3.7.4 Internal Lining

    1 Pipes and fittings shall be lined internally with one of the following linings:

    (a) Polyurethane lining minimum thickness 1,000 micron


    (b) Fusion bonded epoxy powder lining minimum thickness 500 microns
    (c) Ceramic epoxy lining minimum thickness 1,000 micron

    2 All coatings shall be factory applied in strict accordance with the lining manufacturers
    specification. Pipes shall be blast cleaned or ground to the equivalent of BS EN ISO 8501-1,

    .
    BS 7079:A1, SA 2.5 prior to application of the products.

    l
    .l.
    3 All liners shall comply with the following standards:

    rw
    (a) adhesion to pipe (ASTM D4541) Min 10 MPa
    (b) impact resistance (ASTM2794) Min 10 J
    ta
    qa
    (c) abrasion resistance (AST D4060, 1kg x 1000cycles) Max 100 mg
    (d) vapour permeability (ASTM D1653, Wet cup method) 1.0g/m2/24hr
    as

    (e) immersion test 20% sulphuric acid (ASTM D-714-87) No effect after 2 years
    (f) salt spray test (ASTM B117 1,000 hours) pass
    se

    (g) spark holiday test voltage V = 248T0.5, where T = thickness of lining in microns
    er

    (h) any defect found in the lining shall be repaired at the manufacturers plant before
    shipment.
    ov

    4 Internal socket end of pipes shall be protected with a minimum thickness of 300m of epoxy.
    o

    5 All pipes shall be clearly marked to indicate the type of lining as follows:
    it
    et

    (a) PU Polyurethane
    m

    (b) FBE Fusion bonded epoxy


    (c) CE Ceramic epoxy

    3.7.5 External Coating and Wrapping, Use and Materials

    1 External coatings for ductile iron pipes shall be factory applied to the approved pipe
    manufacturers standards and conform to one of the following specifications.
    QCS 2014 Section 08: Drainage Works Page 30
    Part 03: Pipes and Fittings Materials

    Table 3.2 External DI Pipe Coating Systems


    Applicable
    Inner coat Middle Coat Final Coat
    Standards
    200g/m2 zinc 150m epoxy Black fusion or hot melt BS EN 598, BS 6076
    adhesive bonded and ISO 8179-1
    polyethylene sleeving
    of nominal thickness
    1000m

    200g/m2 zinc 150m epoxy Black tape self BS EN 598, ISO 817,
    adhesive bituminous AWWA C2009
    resin on PVC backing
    layer complying with
    AWWA C2009 Section
    24 Type 1. 55%

    l .
    overlap.

    .l.
    rw
    Nil Nil Polyurethane as Part 3 NF A48-851
    3.7.4 minimum
    thickness 2000m

    ta
    qa
    2 Laminate tape shall have the following characteristics:
    as

    Table 3.3 Laminate Tape Properties


    se

    Applicable Pipes Pipes


    Parameter
    Standard 600mm dia 600mm dia
    er

    Overall thickness ASTM D 1000 1.1mm 1.6mm


    ov

    PVC backing thickness ASTM D 1000 0.3mm 0.7mm


    PVC backing thickness if ASTM D 1000 0.5mm 0.5mm
    o

    fabric reinforcement in
    bituminous layer
    it
    et

    Tensile Strength BS 2782 7.5N/mm 12.0N/mm


    m

    Elongation BS 2782 200% 200%

    Tear Resistance ASTM D 1004 19N/mm 50N/mm

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

    Adhesion to self ASTM D 1000 1.8N/mm 1.8N/mm

    Impact resistance (single DIN 30672 8.0Nm 10.0Nm


    layer)
    Dielectric strength BS 2872 25,000V 30,000V

    Insulation resistance BS 2782 1,000,000 1,000,000


    megohms megohms
    Water vapour BS 2782 0.65 0.65
    2 2
    permeability g/m /day g/m /day
    QCS 2014 Section 08: Drainage Works Page 31
    Part 03: Pipes and Fittings Materials

    3 Spigot ends of pipes that are tape or polyethylene wrapped shall not be wrapped over the
    depth of engagement of the spigot with the socket or mechanical coupling but shall be coated
    with a minimum thickness of 300m of epoxy.

    3.7.6 Factory Application of Tape Wrapping

    1 Before primer application, all oil and grease shall be removed with an approved solvent.
    Surfaces to be coated shall be cleaned by mechanical brushing to remove loose corrosion
    products, welding slag, loose factory applied bituminous paint or any other foreign matter and
    achieve a surface finish equivalent to mechanical scraping and wire brushing as specified in
    Clause 8.3.5 of this Section. All surfaces shall be solvent wiped after blast cleaning.

    2 Primer shall be applied to all surfaces to be wrapped immediately following completion of

    l .
    surface preparation.

    .l.
    rw
    3 Primer shall be allowed to dry before wrapping. Primer application shall be limited to the
    amount that can be wrapped during the working day.

    4
    ta
    Tape shall be applied spirally to provide a 55 % overlap and with sufficient tension to result in
    constant adherence without voids or wrinkles. On completion of the wrapping the surface
    qa
    shall be smoothed to ensure completely sealed overlaps and the absence of air pockets
    under the tape. The width of the tape shall be suitable to conform to the size and shape of
    as

    the pipeline being wrapped.


    se

    5 On completion of the wrapping, all tape wrapping shall be checked for continuity by a
    Holiday detection unit. Any Holidays detected shall be repaired by over-wrapping with tape
    er

    and the wrapping retested.


    ov

    6 Bond/adhesion tests shall be carried out on all tape wrappings not more than 24 hours after
    completion of wrapping.
    o

    7 Test certificates shall be provided by the manufacturer.


    it
    et

    3.7.7 Factory Applied Extruded Polyethylene Coating


    m

    1 Extruded polyethylene coating shall be factory applied to preheated epoxy primed pipes and
    fittings to provide a minimum finished thickness of 2.0 mm. The coating shall be resistant to
    peeling, free from imperfections, and shall be tested for continuity using a minimum 10 kV
    spark tester. The polyethylene coating shall be stabilised to prevent ultraviolet and thermal
    degradation.

    3.7.8 Inspection and Testing

    1 Inspection procedures and tests for DI pipes and fittings shall be carried out in accordance
    with BS 4772.

    2 The Contractor shall provide Manufacturers type and quality control test certificates to be
    traced to the pipe cast number, heat number or lot number.

    3 Manufacturers certificates shall state the relevant British or ISO standards to which the pipes
    and fittings supplied comply.
    QCS 2014 Section 08: Drainage Works Page 32
    Part 03: Pipes and Fittings Materials

    4 The repairs to cement mortar linings, if permitted by the Engineer, shall comply with the
    requirements of the designated thickness, minimum bore and surface conditions.

    5 In addition to the prescribed testing, the pipes and fittings shall be subjected to visual
    inspection at the place of manufacturer and at Site and will be rejected if the pipes are
    incorrectly marked or have defects outside the ranges permitted.

    3.8 FLANGE ADAPTERS AND FLEXIBLE COUPLINGS

    3.8.1 General

    1 In addition to the types of joints typically designated for each type of pipe, flange adaptors
    and flexible couplings may be designated particularly for pressure pipelines.

    Flange adaptors and flexible couplings shall:

    l .
    .l.
    (a) be manufactured from rolled steel or other approved materials

    rw
    (b) be capable of withstanding the pressure test of the pipeline in which they are
    incorporated
    (c)
    ta
    permit minimum angular deflection as shown below:
    qa
    Table 3.3 Minimum Angular Deflection
    as

    Pipe diameter (mm) Deflection


    0
    450 6
    se

    0
    450 600 5
    er

    0
    600 750 4
    0
    750 1200
    ov

    3
    0
    1200 -1800 2
    0
    >1800 1
    it o
    et

    (d) be capable of accommodating a movement of 10 mm between ends of pipes they


    connect.
    m

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

    3 Where necessary to restrain movement at joints tied flange adaptors shall be used and the
    deflection criteria shall not apply.

    4 All fasteners shall be stainless steel to BS970 Grade 316S31.

    3.8.2 Flange Adapters

    1 Flange adapters shall be used on PVC-U, GRP, cast and ductile iron, and joints between
    each of the materials as designated. Flanges shall be PN 16 rating and gaskets shall be to
    BS 3063.
    QCS 2014 Section 08: Drainage Works Page 33
    Part 03: Pipes and Fittings Materials

    3.8.3 Flexible Couplings

    1 Flexible couplings shall be used with PVC-U, GRP, cast and ductile iron, and between joints
    between pipes manufactured from each of the materials.

    3.9 PIPES FOR OTHER USE

    3.9.1 Copper Tubes and Fittings

    1 All tubes shall be clean, round, smooth and free from harmful defects and from deleterious
    films in the bore. Copper tubing shall conform to BS EN 1057 and shall be half hard, light
    gauge copper. Tubing shall be supplied in straight lengths by an approved manufacturer
    whose identification mark shall appear on each tube at about 0.5 m intervals. Approved
    dielectric isolation fittings or attachments shall be furnished where copper fittings, piping or

    .
    tubing are connected to ferrous fittings or connections.

    l
    .l.
    2 Copper tubes for internal use shall be in accordance with Table X of BS EN 1057. Chromium

    rw
    plated copper tube shall be of plating quality in accordance with BS 1224, free of defects
    such as blisters, pits, roughness, cracks or unplated areas. Fittings shall be of the
    compression type complying with BS 864 Part 2 and shall be resistant to dezincification.
    ta
    qa
    3 Copper tubes for external use shall be in accordance with Table Y of BS 2871 Part 1. Tubing
    shall have a factory applied green coloured polythene sheath with a minimum thickness of
    1.0 mm. Fittings shall be of the compression or capillary type complying with BS 864 Part 2
    as

    and shall be resistant to dezincification. Joints shall be adequately protected with tape to the
    approval of the Engineer.
    se

    3.9.2 Hose and Appurtenances


    er

    1 Hose and hose reel shall be furnished for designated hose bibbs. Hose shall be 25 mm
    ov

    diameter minimum and provided with an adjustable nozzle. Hose pipes for wash water shall
    be matched to the operating head of the supply system, be constructed for heavy duty and be
    50m long. Hose pipes shall have a certified test pressure of 1.5 times the maximum
    o

    operating pressure. Hose pipes for fire fighting shall be in accordance with Section 23.
    it
    et

    2 Couplings shall be furnished for each size hose, one for each 25 m length of hose provided;
    m

    they shall be of cast brass quick fix type and shall have standard threads.

    3.9.3 Stainless Steel Pipes, Tubes and Fittings

    1 All stainless steel for pipes, tubes and fittings shall be Type 316L.

    2 Stainless steel pipes and tubes shall conform to ASTM A312 and ASTM A688. Plate shall
    conform to ASTM A240; diameters and wall thickness to ANSI B36.19.

    3 Stainless steel fittings and specials shall be compression type conforming to ASTM A234.
    Plate shall conform to ASTM A240; diameters, wall thickness and dimensions to ANSI
    B36.19, ANSI B16.9.
    QCS 2014 Section 08: Drainage Works Page 34
    Part 03: Pipes and Fittings Materials

    4 Pipe sizes 50 mm and smaller shall be of Schedule 40 and above seamless stainless steel
    with threaded ends, and shall conform to material specifications ASTM A312 and
    dimensional specifications ANSI B36.19. Fittings shall be threaded, 2,000 pound forged
    stainless steel, and shall conform to material specification ASTM A182 and dimensional
    requirements of ANSI B16.11.

    5 Unless otherwise designated, pipe sizes over 50 mm shall be Schedule 10 and above,
    seamless stainless steel with bevelled ends for welding conforming to material specification
    ASTM A312 and dimensional specification ANSI B36.19. Unless otherwise designated,
    fittings shall be Schedule 10, seamless stainless steel with bevelled ends for welding and
    conform to material specification ASTM A403 and to the dimensional requirements of
    ANSI B16.9 and ANSI B16.28. Flanges shall be ANSI slip-on or welding neck type, with
    150 pounds rating conforming to material specification ASTM A182 and to the dimensional
    specifications ANSI B16.5.

    l .
    3.9.4 Carbon Steel Pipes and Fittings

    .l.
    rw
    1 Carbon steel pipes shall conform to :

    2 ASTM A53, ASTM A106 for pipes, and ASTM A105 for fittings and flanges

    3 ta
    Carbon steel fittings and flanges shall conform to ASTM A105.
    qa
    3.10 MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES
    as

    3.10.1 Applicable Standards


    se

    1 MDPE and HDPE pipes shall conform to the latest editions of the following standards.
    er

    EN ISO 527 ................Plastics -- Determination of tensile properties


    ov

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

    EN 1519 .....................Plastic piping systems for soil and waste discharge (low and high
    it

    temperature) within the building structure Polyethylene (PE)


    et

    EN ISO 1167 ..............Thermoplastic pipes, fittings and assemblies for the conveyance of
    m

    fluids Determination of the resistance to internal pressure


    EN ISO 1183-2 ...........Plastics Methods for determining the density of non-cellular plastics
    Part 2: Density gradient column method
    EN ISO 2505 ..............Thermoplastics pipes Longitudinal reversion Test method and
    parameters
    EN ISO 3126 ..............Plastics piping systems Plastic components Determination of
    dimensions
    EN ISO 6259 ..............Thermoplastic pipes - Determination of tensile properties
    EN ISO 9080 ..............Plastic piping and ducting systems determination of the long term
    hydrostatic strength of thermoplastics materials in pipe form by
    extrapolation
    EN 12099 ...................Plastics piping systems Polyethylene piping materials and
    components Determination of volatile content
    EN ISO 12162 ............Thermoplastic materials for pipes and fittings for pressure applications
    - Classification and designation Overall service (design) coefficient
    QCS 2014 Section 08: Drainage Works Page 35
    Part 03: Pipes and Fittings Materials

    EN 12201 ...................Plastic piping systems for water supply and for drainage and sewerage
    under pressure Polyethylene (PE)
    EN 12666 ...................Plastic piping systems for non-pressure underground drainage and
    sewerage Polyethylene (PE)
    EN ISO 13479 ............Polyolefin pipes for the conveyance of fluids. Determination of
    resistance to crack propagation.
    EN ISO 15512 ............Plastics Determination of water content
    EN ISO 16871 ............Plastics piping and ducting systems Plastics pipes and fittings
    Method for exposure to direct (natural) weathering
    ISO 18553 ..................Method for the assessment of the degree of pigment or carbon black
    dispersion in polyolefin pipes, fittings and compounds.
    ISO 4065 ....................Thermoplastic pipes Universal wall thickness table
    ISO 4427 ....................Plastics piping systems - Polyethylene (PE) pipes and fittings for water

    l .
    supply

    .l.
    ISO 6964 ....................Polyolefin pipes and fittings Determination of carbon black content

    rw
    by calcination and pyrolysis Test method and basic specification
    ISO 9624 ....................Thermoplastic pipes for fluids under pressure mating dimensions of

    ta
    flange adaptors and loose backing flanges
    ISO 11357-6 ...............Plastics Differential scanning calorimetry (DSC) Part 6:
    qa
    Determination of oxidation induction time (OIT)
    ISO 11922-1 ...............Thermoplastic pipes for the conveyance of fluids Dimensions and
    as

    tolerances - Part: 1: Metric series


    ISO 13761 ..................Plastics pipes and fittings Pressure reduction factors for polyethylene
    se

    pipeline systems for use at temperatures above 20C


    ISO 13953 ..................PE pipes and fittings Determination of tensile strength and failure
    er

    mode of test pieces from a butt-fused joint


    ISO 14236 ..................Plastics pipes and fittings Mechanical joint compression fittings for
    ov

    use with polyethylene pressure pipes in water supply systems


    ASTM D638-10...........Standard test method for tensile properties of plastics
    o

    AWWA C224 ..............Standard for nylon-11 based polyamide coating system for the interior
    it

    and exterior of steel water pipe, connections, fittings and special


    et

    sections
    m

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

    3.10.2 Manufacture

    1 MDPE and HDPE (PE) pipes and fittings shall be manufactured from virgin materials only.
    Recycled, re-ground or re-generated materials shall not be used.

    2 HDPE pressure pipes and fittings shall be manufactured from material conforming to polymer
    classification PE100 having a minimum required strength value (MRS) of 10 MPa at 50 years
    and 20C in accordance with ISO 4427. Design stress shall be 8 MPa. The pipe
    manufacturer shall identify the manufacturer of the resin, the resin type and classification.
    QCS 2014 Section 08: Drainage Works Page 36
    Part 03: Pipes and Fittings Materials

    3 The HDPE pipe material shall be certified as meeting the requirements of the PE100+
    Association.

    4 HDPE pipes to be installed using trenchless technology applications shall be manufactured


    from a PE100-RC material. Pipes manufactured from such material shall have undergone the
    Notched Pipe Test at an independent 3rd party laboratory in accordance with ISO 13479 and
    the time to failure shall have been a minimum of 8,760 hours (1 year). All other
    characteristics shall comply with the PE100 requirements of ISO 4427 and this specification.

    5 HDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
    the Engineer and shall have a pressure rating of 16 bar (PN16) at 20C (de-rated to 11.8 bar
    at 40C, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by the
    Engineer.

    6 Pipes and fittings shall be designed to achieve a minimum working life of 50 years under all

    l .
    applicable loads, environmental and installation conditions.

    .l.
    rw
    7 MDPE pressure pipes and fittings shall be manufactured from material conforming to
    polymer classification PE80 having a minimum required strength value (MRS) of 8 MPa at 50
    years and 20C in accordance with ISO 4427. Design stress shall be 6.4 MPa. The pipe

    ta
    manufacturer shall identify the manufacturer of the resin, the resin type and classification.
    qa
    8 MDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
    the Engineer and shall have a pressure rating of 12.8 bar (PN12.8) at 20C (de-rated to 9.5
    as

    bar at 40C, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by
    the Engineer.
    se

    9 Pipes and fittings shall be homogeneous throughout and free of visible cracks, holes, foreign
    er

    inclusions, voids and other injurious defects.


    ov

    10 The resin from which the pipes and fittings are manufactured shall comply with the
    requirements of ISO 4427 Part 1 and be protected from UV attack by the addition of carbon
    black in accordance with the standard.
    it o

    11 Straight lengths of PE pipe shall be supplied in standard lengths of 12m (-0/+50 mm)
    et

    measured at 23C 2C. Unless otherwise specified, coil length shall not exceed 100m.
    Coiled pipes shall be coiled such that localised deformation is avoided and the minimum
    m

    internal diameter of the coil shall not be less than 20 x outside diameter. Prior to jointing the
    degree of pipe ovality shall not exceed the permissible levels given in Table 1 of ISO 4427,
    Part 2 and the Contractor shall, if required, use mechanical re-rounding equipment to meet
    these requirements. Field cut lengths of pipe used as closures may not be shorter than 0.75
    metre in length and shall be approved by the Engineer.

    12 All pipes shall be indelibly marked at intervals of maximum 1m. The colour of the pipe
    marking shall always contrast with the colour of the pipe. Markings shall include the following
    information:

    (a) Manufacturers name, trademark


    (b) Material and designation i.e. PE100
    (c) The nominal pressure (PN) of the pipe / fitting
    (d) Dimension of the pipe (nominal outside diameter x nominal wall thickness)
    QCS 2014 Section 08: Drainage Works Page 37
    Part 03: Pipes and Fittings Materials

    (e) Standard Dimension Ratio (SDR)


    (f) Production period (date / batch code)
    (g) International Standard to which the pipe / fitting has been produced to
    (h) Designation of the medium for which the pipe is produced for (water, gas, sewage)
    (i) Stencilled in legible letters the pipe identification number on the outside at each end.
    Ensure that the same number appears on all record sheets and documents relating to
    the manufacture, delivery and testing of that pipe.

    13 Pipes shall be delivered in wooden frames or similar arrangement to avoid movement


    between pipes. Pipes shall not be stacked higher than 1m in each frame or packing
    arrangement.

    3.10.3 Fittings

    l .
    .l.
    1 Unless otherwise specifically approved by the Engineer, all PE pressure pipe fittings for use
    with pipes of up to 355 mm OD shall be injection moulded with the same polymer

    rw
    classification, material type and pressure rating as the pipe to which they are to be
    connected. All joints between PE pipes and fittings shall whenever possible be by thermal

    ta
    butt fusion welding or electro-fusion welding process.
    qa
    2 Connections of PE pipes and fittings to metallic fittings shall be made with PN16 backing
    rings with a stainless steel stiffener insert or as recommended by the pipe or fitting
    manufacturer and approved by the Engineer.
    as

    3 Transition fittings used to join the pipe to flanged fittings and pipes made of other materials
    se

    shall be certified by an independent third party as being fully compliant with the Type 1 or
    Type 2 requirement of WIS 4-24-01 i.e. they shall prevent the pull out of the pipe at their
    er

    rated operational and test pressures.


    ov

    4 Metallic fittings shall be fully coated to provide protection against corrosion. The coating shall
    be a factory applied fusion bonded epoxy or a nylon 11 based polyamide coating system,
    o

    have a minimum dry film thickness of 250 microns and comply with the requirements of
    it

    either AWWA C224 or WIS 4-52-01. Any bolts, studs or nuts shall be of stainless steel
    et

    (grade 304 or better) or else be protected with a coating that complies with the requirements
    of WIS 4-53-03. All buried metallic fittings shall be protected by petroleum impregnated
    m

    primer, paste and tape prior to back filling.

    5 Where their use is approved by the Engineer, all compression fittings shall be certified by an
    independent third party as being fully compliant with the requirements of ISO 14236. They
    shall be tested and certified as being class 1 end load bearing fittings i.e. they shall prevent
    the pull out of the pipe at their rated operational pressure. Only materials listed in Tables 1
    and 2 of ISO 14236 shall be used in the manufacture of the fitting body.

    6 Where the use of fabricated fittings has been specifically approved by the Engineer such
    fittings shall be designed and manufactured in accordance with the requirements of ISO
    4427, Part 3, in particular Annex B. The pressure derating factors to be employed by the
    fittings fabricator shall be in accordance with annex sections B3 and B5 unless they can
    demonstrate that higher factors can be applied. The use of any higher factors shall be
    approved by the Engineer prior to commencement of fitting fabrication.

    7 All PE fittings shall, as a minimum, be indelibly marked with the following information:
    QCS 2014 Section 08: Drainage Works Page 38
    Part 03: Pipes and Fittings Materials

    (a) Manufacturers name, trademark


    (b) International Standard to which the pipe / fitting has been produced to
    (c) Material and designation i.e. PE100
    (d) The nominal pressure (PN) of the pipe / fitting
    (e) Outside diameter and Standard Dimension Ratio (SDR)
    (f) Production period (date / batch code)

    8 PE Fittings shall be individually packed in bulk, bag or individual protection against


    contamination. Electrofusion fittings shall always be packed in a sealed bag or container. The
    packaging shall, as a minimum, be labelled with the manufacturers name, quantity, type and
    dimension.

    3.10.4 Pipes and Fittings for Gravity Applications

    l .
    .l.
    1 Pipes and fittings for drainage applications shall be suitable for carrying potable water,

    rw
    treated sewage effluent, raw sewage and surface water at temperatures up to 40C as
    dictated by the particular application and they shall comply with the requirements of EN1519
    or EN 12666, as appropriate.

    ta
    qa
    3.10.5 Testing of MDPE and HDPE Pressure Pipes and Fittings

    1 The raw material and pipe manufacturers shall document and certify all products and shall
    as

    undertake all testing required by ISO 4427 and this specification.


    se

    2 Prior to delivery of any pipes or fittings the pipe manufacturer shall provide the Engineer with
    a comprehensive Inspection and Testing Plan (ITP) for their approval. The ITP shall detail all
    er

    the certificates and documents that shall be provided by the pipe manufacturer, together with
    details of the testing that they shall undertake, its frequency and associated test reports.
    ov

    Where the pipe manufacturer cannot themselves undertake the required testing they shall
    employ an independent third party laboratory to undertake the testing on their behalf.
    o

    3 Definition of material, pipe and fittings batches for the purposes of batch release testing:
    it
    et

    (a) A raw material batch shall be considered as a batch of material supplied by the resin
    producer having an individual identification number or code. For the purposes of this
    m

    specification it shall also be the raw material used to manufacture a particular pipe
    batch.
    (b) A pipe batch shall be considered as a continuous production run of a particular pipe
    OD and wall thickness manufactured from one resin type with no change in the
    manufacturing process.
    (c) A batch of fabricated fittings shall be considered as group of fittings of the same OD
    and wall thickness.

    4 The pipe manufacturer shall undertake the following minimum batch release testing.
    QCS 2014 Section 08: Drainage Works Page 39
    Part 03: Pipes and Fittings Materials

    Table 1 Release tests to be undertaken on each raw material batch

    Sampling No. of Tests or


    Characteristics Reference
    Frequency Inspections

    Once per raw


    Compound Density ISO 4427-1 section 4 1
    material batch
    Once per raw
    Oxidation induction time ISO 4427-1 section 4 1
    material batch
    Once per raw
    Melt mass-flow rate ISO 4427-1 section 4 1
    material batch

    l .
    .l.
    Table 2 Release inspections and tests to be undertaken on each batch of pipes

    rw
    Characteristics Reference Sampling No. of Tests or
    Frequency Inspections
    Appearance and colour ISO 4427-2 section 5
    ta
    Continuously -
    qa
    Geometrical ISO 4427-2 section 6 Continuously -
    as

    Marking This specification Each pipe or coil 1


    se

    Melt mass-flow rate ISO 4427-2 section 8 Once per pipe batch 1
    er

    Elongation at break ISO 4427-2 section 8 Once per pipe batch 1


    ov

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

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

    Longitudinal reversion ISO 4427-2 section 8 Once per pipe batch 1


    m

    Pipe wall thickness shall be measured and controlled on a continuous basis using and ultrasonic
    thickness gauge or similar device that shall be regularly calibrated in accordance with the gauge
    manufacturers recommendations.

    5 In accordance with the recommendations of ASTM D 638, the maximum thickness of the
    tensile strength test samples cut from the pipe wall shall be 14 mm. In the event of the pipe
    wall being thicker than 14 mm the pipe manufacturer shall machine the test samples in
    accordance with the Table 3.
    QCS 2014 Section 08: Drainage Works Page 40
    Part 03: Pipes and Fittings Materials

    Table 3 Preparation of samples for tensile testing


    Pipe Wall Thickness (WT) Test Sample Thickness No. of samples to be
    (mm) (mm) taken from the pipe wall

    14 WT 1

    14 < WT 28 WT/2 2

    28 < WT 42 WT/3 3

    42 < WT 56 WT/4 4

    56 < WT 72 WT/5 5

    All testing shall be undertaken in accordance with ISO 6259 and all HDPE samples shall
    achieve a minimum tensile strength at yield of 19 MPa in order for the pipe to successfully
    pass the test. MDPE samples shall have achieved minimum tensile yield strength at yield of

    l .
    15 MPa.

    .l.
    rw
    Table 4 Release inspections and tests to be undertaken on each batch of fabricated fittings

    Characteristics Reference Sampling No. of Tests or

    Appearance and colour ISO 4427-2 section 5 ta Frequency


    Continuously
    Inspections
    -
    qa
    Geometrical ISO 4427-2 section 6 Continuously -
    as

    Marking This specification Each fitting 1


    o
    Hydrostatic strength at 20 C, ISO 4427-3 Annex B Once per batch of 1 piece only
    se

    100hrs & 12.4MPa x HDPE fittings


    o
    er

    Hydrostatic strength at 20 C, ISO 4427-3 Annex B Once per batch of 1 piece only
    100hrs & 10 MPa x MDPE fittings
    ov

    The fabricated fitting to be hydrostatically tested shall be a tee or branch provided the batch
    in question contains this type of fitting, otherwise a bend shall be tested.
    it o

    6 In the case of injection moulded fittings the manufacturer shall issue a certificate confirming
    et

    compliance with ISO 4427 and providing details of the type testing undertaken by an
    independent third party in accordance with sections 7 and 8 of ISO 4427 Part 3.
    m

    7 The pipe manufacturer shall provide the Engineer with a copy of the batch release tests i.e.
    all those tests listed above, with each batch of pipes or fittings that is delivered to site.

    8 Prior to delivery of pipes the pipe manufacturer shall provide the Engineer with copies of all
    the test results and certification required by ISO 4427, this specification and the ITP, but
    which are not covered by the above batch testing requirements. These documents shall
    comprise the Type Test Report.

    9 The Type Test Report shall include a copy of the raw material manufacturer's "Certificate of
    Quality Control Testing" covering each batch of raw material used for manufacturing pipes
    produced under this specification.

    10 The pipe manufacturer shall ensure that all the applicable codes and standards are available
    at their facility for the Engineers reference during any visit or inspection.
    QCS 2014 Section 08: Drainage Works Page 41
    Part 03: Pipes and Fittings Materials

    11 The pipe manufacturer shall provide full assistance and co-operation for any inspection,
    when required by the Engineer or by an inspector appointed by the Engineer.

    12 The Engineer may reject any item that does not successfully pass the required tests or fully
    comply with the requirements of this specification. When a pipe or fitting is rejected, the items
    manufactured immediately before or after shall be carefully examined and tested at the
    direction of the Engineer. If further defects are found, the entire batch shall be rejected.

    13 All pipes and fittings shall be visually inspected by the PE Welding Inspector before
    incorporation in the Works.

    14 In addition to those tests specifically required, the Engineer may request additional samples
    of any material for testing by the Engineer and all expenses incurred in obtaining samples for
    testing shall be borne by the Contractor at no additional cost to the Contract.

    l .
    3.11 POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-

    .l.
    PRESSURE DRAINAGE AND SEWERAGE

    rw
    3.11.1 General

    1 ta
    Polyester resin concrete is a mixture formed from aggregates and fillers which are bound
    qa
    together using a polyester resin (also called Polymer concrete pipes), as defined in ISO
    18672-1 or ASTM D 6783 with the amendments given below.
    as

    2 Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems
    (pipes, manhalls, soakways).
    se

    3.11.2 Resin
    er

    1 The resin used in the pipe system and manufactured as per ISO 18672-1shall have a
    ov

    temperature of deflection of at least 85 C, when tested in accordance with Method A of


    ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the
    o

    applicable requirements of EN 13121-1.


    it

    2 The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a
    et

    minimum deflection temperature of 85C when tested at 1.82 MPa following Test Method
    m

    D648. The resin content shall not be less than 7% of the weight of the sample as determine
    by test method D2584

    3.11.3 Minimum strength

    1 The minimum strength classes for different pipe shapes are given below
    Table 3.11.1
    Minimum strength classes for pipes designated PRC-OC or PRC-TC
    Strength class
    Nominal size Sc
    DN N/mm
    PRC-OC PRC-TC
    150 DN 500 180 180
    600 DN 1000 145 160
    1200 DN 3000 120 145
    QCS 2014 Section 08: Drainage Works Page 42
    Part 03: Pipes and Fittings Materials

    Table 3.11.2
    Minimum strength classes for pipes designated PRC-OE or PRC-TE
    Strength class
    Nominal width/height Sc
    WN/HN
    N/mm

    PRC-OE PRC-TE

    300/450 WN/HN 600/900 180 180

    700/1050 WN/HN 1000/1500 145 160

    1200/1800 WN/HN 1400/2100 120 145

    l .
    .l.
    rw
    Table 3.11.3
    Minimum strength classes for pipes designated PRC-OK or PRC-TK

    Nominal size ta
    Strength class
    Sc
    qa
    DN N/mm
    PRC-OK PRC-TK
    as

    800 DN 1000 145 160


    se

    1200 DN 1800 120 145


    er
    ov
    o

    END OF PART
    it
    et
    m
    QCS 2014 Section 08: Drainage Works Page 1
    Part 04: Pipeline Installation

    4 PIPELINE INSTALLATION ............................................................................ 3

    4.1 GENERAL ...................................................................................................... 3


    4.1.1 Scope of Work 3
    4.1.2 References 3
    4.1.3 Guidelines 4
    4.1.4 Definitions 4
    4.1.5 Submittals 4
    4.1.6 Quality Assurance 5
    4.1.7 Delivery, Storage and Handling 5
    4.1.8 Specialists, Inspection and Testing 5
    4.1.9 Soil Corrosivity Study 6
    4.1.10 Setting Out and Pipeline Alignment 6

    l .
    4.1.11 Tools for Installation and Testing 6

    .l.
    4.1.12 Inspection During Installation 6

    rw
    4.1.13 Dewatering 7
    4.1.14 Closures and Short Sections 7
    4.1.15 Cutting of Pipes 7
    4.1.16 Stringing of Pipes
    ta 7
    qa
    4.1.17 Inspection of Trench Formation 8
    4.1.18 Overpumping and Flow Diversions 8
    4.1.19 Other Services 8
    as

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


    se

    GRP PIPELINE JOINTING ............................................................................ 8


    4.2.1 Push-fit Joints 8
    er

    4.2.2 Mechanical Joints 9


    4.2.3 Flanged Joints 9
    ov

    4.2.4 GRP Joints 9


    4.3 MDPE AND HDPE PIPELINE JOINTING .................................................... 10
    it o

    4.3.1 General 10
    et

    4.3.2 PE Welding Technicians 10


    4.3.3 PE Welding Inspectors 10
    m

    4.3.4 PE Welding Equipment 11


    4.3.5 Method Statements 11
    4.3.6 Electrofusion Jointing 11
    4.3.7 Electro-fusion Joint Inspection 12
    4.3.8 Butt Fusion Jointing 12
    4.3.9 Butt Fusion Joint Inspection 13
    4.3.10 Testing of Fusion Joints 13
    4.3.11 Anchorage 13
    4.4 PIPE LAYING .............................................................................................. 14
    4.4.1 General 14
    4.4.2 Laying of Rigid and Semi-Rigid Pipes 15
    4.4.3 Laying of Flexible MDPE and HDPE Pipes 16
    4.4.4 Laying of GRP Pipes 16
    4.4.5 Corrosion Protection of Ferrous Pipelines 18
    QCS 2014 Section 08: Drainage Works Page 2
    Part 04: Pipeline Installation

    4.4.6 Concrete Protection to Pipe 19


    4.4.7 Deflection Criteria for Flexible Pipelines 20
    4.4.8 Backfilling 20
    4.4.9 Deflection at Joints 21
    4.4.10 Wadi Crossings 21
    4.4.11 Pipe Supports 22
    4.4.12 Building-in Pipes to Structures 22
    4.4.13 Cleanliness of Pipelines 23
    4.4.14 Marker Tape 24
    4.4.15 Pressure Pipeline Marker Posts 24
    4.4.16 Valve Chamber Marker Posts 24
    4.4.17 Abandonment of Pipelines 24
    4.4.18 Abandonment of Structures 25
    4.4.19 Corrosion Protection of Flexible Couplings and Ferrous Fittings 25

    l .
    .l.
    4.5 PIPELINE STRUCTURES AND APPURTENANCES .................................. 26

    rw
    4.5.1 Manholes for Foul Sewerage 26
    4.5.2 Manholes for Surface Water Sewerage 28
    4.5.3 Chambers 28
    4.5.4 Connections to Existing Pipelines ta 28
    qa
    4.5.5 Anchor and Thrust Blocks 29
    4.5.6 Property Connections Survey 29
    4.5.7 Future House Connections 29
    as

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


    se

    4.6.1 General 30
    4.6.2 Gravity Sewer Pipelines 31
    er

    4.6.3 Pressure Pipelines 32


    ov

    4.6.4 Other Pressure Pipelines 33


    4.6.5 MDPE and HDPE Pressure Pipelines 34
    o

    4.7 MISCELLANEOUS ITEMS .......................................................................... 38


    it

    4.7.1 Manhole Covers and Frames 38


    et

    4.1.2 Duct Covers and Frames 39


    m

    4.7.2 Hinged Aluminium Access Covers 40


    4.8 FUTURE SEWER CONNECTION ............................................................... 40
    4.8.1 General 40
    4.9 INSITU LINING OF EXISTING MANHOLES ............................................... 41
    4.9.1 General 41
    QCS 2014 Section 08: Drainage Works Page 3
    Part 04: Pipeline Installation

    4 PIPELINE INSTALLATION
    4.1 GENERAL

    4.1.1 Scope of Work

    1 This Part includes the installation of pipelines.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, General
    Part 2, Earthworks
    Part 3, Pipes and Fittings Materials
    Part 5, Valves, Penstocks and Appurtenances

    .
    Part 6, Miscellaneous Metal Works

    l
    .l.
    Part 7, Miscellaneous GRP Works

    rw
    Part 8, Protective Coatings and Painting

    Section 1, General
    Section 2,
    Section 3,
    Demolition and Alterations
    Ground Investigation ta
    qa
    Section 5, Concrete.
    4.1.2 References
    as

    1 The following standards are referred to in this Part:


    se

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


    BS 4872......................Approval testing of welders when welding procedure approval is not
    er

    required
    ov

    BS 6072......................Tubular polyethylene film for use as a protective sleeving for buried


    iron pipes and fittings
    BS EN 752..................Drain and sewer systems outside buildings
    it o

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


    et

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


    and including 16 bar, Part 2: Specific functional recommendations for
    m

    PE
    ISO 12176 ..................Plastics pipes and fittings Equipment for fusion jointing polyethylene
    systems, Parts 1 and 2
    ISO 21307 ..................Plastics pipes and fittings Butt fusion jointing procedures for
    polyethylene (PE) pipes and fittings used in the construction of gas
    and water distribution systems
    ISO 13953 ..................Polyethylene (PE) pipes and fittings - Determination of the tensile
    strength and failure mode of test pieces from a butt fused joint
    ISO 13954 ..................Plastics pipes and fittings - Peel decohesion test for polyethylene (PE)
    electrofusion assemblies of nominal outside diameter greater than or
    equal to 90 mm
    SFS 3115:E ................Plastics Pipes Water Tightness Test for Pressure Pipelines (English
    version of Finnish Standard)
    WIS-4-08-02 ...............Specification for bedding and sidefill materials for buried pipelines
    QCS 2014 Section 08: Drainage Works Page 4
    Part 04: Pipeline Installation

    AWWA C200 ..............Steel Water Pipe 150 mm and Larger


    AWWA C600 ..............Installation of Ductile-Iron Water Mains and Their Appurtenances.

    4.1.3 Guidelines

    1 The following Guidelines are applicable to the installation and testing of HDPE pipes and
    fittings:
    DVGW GW330...........Installation & Welding of High Density Polyethylene (HDPE) Pipes for
    Gas & Water Applications
    DVGW GW331...........Supervision of Installation & Welding of High Density Polyethylene
    (HDPE) Pipes for Gas & Water Applications
    DVS 2202-1 ................Imperfections in thermoplastic welded joints: Features, description,
    evaluation

    l .
    DVS 2203-1 ................Testing of welded joints of thermoplastic sheets and pipes: Test

    .l.
    methods Requirements

    rw
    DVS 2207-1 ................Welding of thermoplastics: Heated tool welding of pipes, pipeline
    components and sheets made of HDPE
    DVS 2208-1 ................Welding of thermoplastics: Machines and devises for the heated tool
    ta
    welding of pipes, pipe parts and panels
    qa
    4.1.4 Definitions
    as

    1 Pipes: circular tubes through which fluid can flow including manufactured lengths of pipes,
    bends, fittings, junctions and other specials, joints and jointing parts.
    se

    2 Valves: manufactured devices for controlling the passage of fluids through pipes including
    er

    sluice gates, reflux valves, and air valves including associated joints, jointing parts, operating
    gear and fittings.
    ov

    3 Installation: material transport and handling, pipelaying including the complete operation of
    laying jointing and testing pipes in trenches or elsewhere, and the construction of pipeline
    o

    ancillaries
    it
    et

    4 Pipeline: long, continuous line of pipes and fittings including valves and ancillary structures
    and equipment used for transporting fluids; specifically, sewers and ancillary works for the
    m

    transport of sewage and surface water and similar pipelines for the transport of treated
    sewage effluent.

    4.1.5 Submittals

    1 The Contractor shall submit the documents described in the following paragraphs.

    2 Working drawings: Before commencing work the Contractor shall prepare working drawings
    necessary for the construction and installation of facilities. The drawings shall be prepared to
    A1 size or a size and scale as directed by the Engineer. The drawings shall be submitted to
    the Engineer in an orderly manner and at periods which will permit adequate time for review
    and approval by the Engineer. Five copies of drawings shall be submitted.

    3 Detailed work programme with schedule for the delivery of pipes and fittings
    QCS 2014 Section 08: Drainage Works Page 5
    Part 04: Pipeline Installation

    4 Methods statements to supplement the working drawings, as follows:

    (a) installation
    (i) joints and couplings
    (ii) measures to ensure integrity of interior pipe lining and exterior protective
    coating at joints and couplings
    (iii) installation and adjustment of pipe bedding and other supports
    (iv) fitting of pipelines to valves.
    (b) testing of sewer pipelines and pressure pipelines to the requirements described
    in Subpart 4.5
    (c) welding procedures and electrodes with drawings and schedules as may be
    necessary

    .
    (d) safety procedures and protective equipment

    l
    .l.
    5 Quality assurance and control documents including

    rw
    (a) certified copies of reports of required tests including:
    (i)
    (ii)
    pipe pressure tests
    dielectric joint tests ta
    qa
    (b) copies of certificates relating to welders tests shall be made available to the
    Engineers on request
    as

    4.1.6 Quality Assurance


    se

    1 A suitably qualified and experienced safety officer shall be employed to ensure that all
    Contractors employees follow safety procedures and are provided with appropriate safety
    er

    and protective equipment.


    ov

    2 Welders employed on the fabrication and site welding shall have passed the welder approval
    tests of BS 4872, Part 1 or other standard approved by the Engineer.
    o

    4.1.7 Delivery, Storage and Handling


    it
    et

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


    m

    2 The Contractor shall replace or repair pipe damaged during handling and installation, to the
    approval of the Engineer.

    4.1.8 Specialists, Inspection and Testing

    1 The Employer may employ the services of a specialist firm to assist the Engineer as he may
    require in any matter connected with pipes, and fitting including the inspection of materials
    and workmanship and the witnessing of tests at any stage during the execution and
    maintenance of the Works.

    2 Such independent tests may be carried out at any stage during the execution and
    maintenance of the Works, but they shall not relieve the Contractor of his obligations under
    the Contract.

    3 To the extent ordered by the Engineer, the Contractor shall provide labour, plant, tools and
    materials (but not special testing equipment) for direct assistance to the specialist firm in their
    inspection and independent testing and for any further work, investigations, and repairs which
    the Engineer considers necessary as a result of such inspection or testing.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 04: Pipeline Installation

    4 The provision of labour, plant and materials as aforesaid shall be an obligation of the
    Contractor where in the Engineer's opinion the inspection test or further investigation shows
    that materials and workmanship provided by the Contractor do not comply with the
    designated requirements.

    4.1.9 Soil Corrosivity Study

    1 Where designated in the Project Specification, the Contractor shall carry out a soil corrosivity
    study along the route of proposed ferrous pipelines as directed by the Engineer and mark the
    results on the pipeline layout plans.

    2 Soil resistivities shall be undertaken using a low resistance, null-balance earth tester and a
    four pin array, or any other equipment approved by the Engineer. Readings shall be
    recorded in ohm-cm and shall be taken at 1.0 m incremental depths to a depth 1 m below the
    pipeline invert levels. Readings shall be taken at a spacing along the route of the proposed
    pipelines as required to reflect the changing soil conditions, but in no case shall the spacing

    .
    exceed 500 m.

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    .l.
    rw
    3 Soil samples shall be taken as directed by the Engineer along the route of the proposed
    pipelines at a maximum spacing of 500 m. Soil samples shall be tested for sulphates,
    sulphides, chlorides, pH, moisture content, and carbonates.

    4.1.10 Setting Out and Pipeline Alignment ta


    qa
    1 All sewers shall be laid accurately to the lines, and levels gradients shown on the approved
    drawings so that the pipeline is straight between successive manholes in the vertical and
    as

    horizontal planes.
    se

    2 Pressure pipelines shall be laid accurately to the lines levels and depths shown on the
    approved drawings. Where changes of direction are required, deflections shall be made in
    accordance with the manufacturers recommendations.
    er

    3 Manufactured bends shall only be used where shown on the Drawings or where otherwise
    ov

    permitted by the Engineers Representative.


    o

    4 Where pipelines of constant gradient are to be laid, the Contractor shall provide, fix and
    maintain at such points as may be directed by the Engineers Representative properly
    it

    painted sight rails and boning rods of pre-determined measurement for the boning in of
    et

    individual pipes to correct alignment. The sight rails shall be situated vertically over the line of
    pipes or immediately adjacent thereto and there shall at no time be less than three sight rails
    m

    in position on each length of pipeline under construction to any one gradient

    5 If the Contractor wishes to propose an alternative method of controlling pipeline alignment,


    he shall submit his proposed method to the Engineers Representative for approval

    4.1.11 Tools for Installation and Testing

    1 The Contractor shall supply all necessary tools for cutting, chamfering, jointing, testing and
    for any other requirement for satisfactory installing the pipelines.

    4.1.12 Inspection During Installation

    1 Pipes and fittings including any sheathing, inside linings and outside coatings, shall be
    inspected by the Contractor immediately before and after installation, and damage or other
    imperfection shall be repaired by the Contractor as directed by the Engineer before
    installation and in accordance with the following:
    QCS 2014 Section 08: Drainage Works Page 7
    Part 04: Pipeline Installation

    (a) Material required for the repair of pipe, sheathing, linings and coatings shall be
    obtained by the Contractor and shall be used in accordance with the manufacturers
    recommendations.
    (b) Without relieving the Contractor of any of his obligations, the Engineer may inspect
    and test the pipe and appurtenances by any appropriate means, and damage
    discovered by such inspection shall be repaired by the Contractor.
    (c) The Contractor shall remove from Site any pipe or appurtenance which in the
    opinion of the Engineer is so damaged as to be unfit for incorporation in the Works.
    The obtaining of replacements for damaged pipes and fittings to the approval of the
    Engineer shall be an obligation of the Contractor.

    4.1.13 Dewatering

    1 All pipeline installation work shall be carried out in the dry.

    .
    2 Dewatering shall be carried out as specified in Part 2 of this Section.

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    4.1.14 Closures and Short Sections

    rw
    1 For the purpose of reducing the angular deflections at pipe joints, and for closure sections,
    the Contractor will be permitted to install pipe sections of less than standard length. Closing

    ta
    lengths and short sections of pipes of all types shall be fabricated and installed by the
    Contractor as found necessary at Site. Where closing pieces are required, the Contractor
    qa
    shall make all necessary measurements and shall be responsible for the correctness thereof.
    The Contractor shall be responsible for taking the measurements required to determine the
    lengths of cut portions of pipes for insertion as closing lengths in pipelines.
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    4.1.15 Cutting of Pipes


    se

    1 Where pipes are required to be cut on the Site the cutting shall be done by the Contractor in
    accordance with the manufacturers recommendations and in a manner approved by the
    er

    Engineer.
    ov

    2 The pipe and methods of jointing shall be such that the locations of fittings and lengths of
    pipe can be adjusted to suit Site conditions.
    o

    3 Cutting of reinforced concrete pipes will not be allowed. Special lengths of pipes shall be
    it

    manufactured for closures as required. Other pipes such as GRP, ductile iron, vitrified clay,
    et

    MDPE, HDPE, PVC-U and cast iron pipes shall only be cut if approved by the Engineer.
    m

    4 The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes for inserting
    specials, fittings or closure pieces shall be carried out as follows:

    (a) Cutting shall be carried out in a neat and workmanlike manner with an approved
    cutting machine without damage to the pipe and so as to leave a smooth end at right
    angles to the axis of the pipe.
    (b) Cutting by hacksaw shall not be permitted unless approved by the Engineer.
    (c) Only experienced men shall be employed by the Contractor on this work.
    (d) The Contractor shall take every precaution to ensure that both the measurement
    tolerances and the cutting of pipes are to the accuracy required. Should any errors
    occur the Contractor shall correct the defects to the approval of the Engineer.

    4.1.16 Stringing of Pipes

    1 Pipes shall be distributed to installation site only in such quantities as can be installed in one
    working day or as allowed by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 8
    Part 04: Pipeline Installation

    2 The Contractor shall take pipes from the storage areas, unload and string along the route of
    the proposed pipeline. Pipes shall be so strung as to cause the least practicable interference
    with the use of the land.

    3 After a pipe has been strung and immediately before being laid, it shall be cleaned out and
    inspected for defects. Cast or ductile iron pipes shall be rung with a light hammer while the
    pipe is suspended clear of the ground to detect cracks. Other pipes shall be visually
    inspected. Any defective, damaged or unsound pipe shall be rejected. Any damage to the
    lining or coating of the pipe shall be repaired or the pipe rejected as directed by the Engineer.

    4 Plastic pipes shall not be strung along the pipe route but shall be stored in accordance with
    Part 3 of this Section until required for laying and jointing.

    4.1.17 Inspection of Trench Formation

    1 After excavations have been completed to the designated levels and, trench formation

    .
    compacted, the Contractor shall issue a formal notice to the Engineer that the trench

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    .l.
    formation is ready between designated points for inspection. The Engineer will without
    unreasonable delay inspect the said trench formation, unless he considers it unnecessary

    rw
    and advises the Contractor accordingly. Any rejection of trench formation will be confirmed in
    writing by the Engineer.

    2
    ta
    The formation will be re-inspected by the Engineer after replacement of any unsound material
    with material as specified under Clause 2.2.3 of Part 2 of Section 8.
    qa
    3 No bedding shall be placed until the Engineers Representative has given his approval to the
    trench formation.
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    4.1.18 Overpumping and Flow Diversions


    se

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


    er

    4.1.19 Other Services


    ov

    1 Where the Works requires the seeking, protection, diversion or relocation of existing services
    the procedures set out in Section 6 Part 11 shall be followed.
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    4.2 DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND GRP
    et

    PIPELINE JOINTING
    m

    4.2.1 Push-fit Joints

    1 Immediately before assembling each joint incorporating a rubber ring seal, the rubber shall
    be inspected for cracks, every part of the ring being deformed by hand to about 150 mm
    radius. If under this deformation any cracks are either revealed or initiated then the ring shall
    be rejected, cut through completely to prevent inadvertent use, and the matter reported
    forthwith to the Engineer. If more than three successive rings inspected in this way are
    rejected the Contractor shall on the instruction of the Engineer stop all pipe jointing until the
    cause of the defect has been proved and remedied to his satisfaction.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 04: Pipeline Installation

    2 The rubber ring shall be placed in the groove on the socket or spigot ring. The groove shall
    be free of deleterious material; e.g., dirt, moisture, oil, and grease. The inside surface of the
    socket shall be lubricated with a compound recommended by the manufacturer which will
    facilitate the telescoping of the joint. The spigot end of the pipe shall then be inserted into the
    socket of the adjoining pipe using a suitable tool to push the spigot into the socket. The
    position of the pipe and the gasket in the joint shall then be checked using a feeler gauge to
    demonstrate proper jointing. When joints are not properly made, pipes shall be adjusted, or
    removed and rejointed as necessary to ensure proper jointing. Care shall be taken to avoid
    twisting or cutting the ring when jointing the pipe.

    3 For pipes up to and including 700 millimetres nominal bore the joints shall be capable of
    withstanding a deflection of not less than 1.5 degrees in any direction and for pipes over 700
    millimetres nominal bore 0.5 degrees in any direction. All pipe joints shall be capable of
    withstanding a draw of 13 millimetres over and above the initial jointing allowance. The
    initial jointing allowance is the gap between the spigot and the shoulder of socket measured
    parallel to the centre line of the pipeline and shall not be less than 6 millimetres or greater

    .
    than 13 millimetres.

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    4.2.2 Mechanical Joints

    rw
    1 Where mechanical joints are approved, installation shall be in accordance with the
    manufacturers recommendations. The Contractor shall render the end of each pipe perfectly

    ta
    smooth so as to allow the joint sleeve to slide freely and where necessary shall coat the pipe
    ends with two coats of an approved quick drying sealing and protective compound. Buried
    qa
    joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied as
    clause 4.3.5.
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    4.2.3 Flanged Joints


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    1 Flanged joints for ductile iron and cast iron pipes and specials shall be made with rubber joint
    gaskets and steel bolts and nuts which shall include two washers per bolt. The use of jointing
    paste or grease shall not be permitted. The gasket may be fastened to the bolts with cotton
    er

    thread. The bores of abutting pipes or fittings shall be concentric and no jointing material is
    to be left protruding into the bore.
    ov

    2 All nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference
    shall then be alternately and progressively tightened with a spanner so as to ensure even
    o

    pressure all around the joint.


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    et

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

    1 Joints shall be of the O ring or rolling type, and shall incorporate a soft or flexible control
    register to help to locate the joint.

    2 GRP pipe joints shall be assembled in accordance with manufacturer's instructions for the
    type of flexible joint provided.

    3 Joints shall be capable of withstanding the various tests specified for the appropriate class of
    pipe. Joints shall withstand, while maintaining the specified test pressure, a deflection of not
    less than 1.5 in any direction or for pipes up to and including 600 mm nominal bore, and
    0.5 in any direction for pipes over 600 mm diameter.

    4 Rubber joint rings shall be made of EPDM SBR or nitrile rubber (NBR) and shall comply with
    the relevant requirements of BS EN 681-1 for Type WG rings.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 04: Pipeline Installation

    5 Flanged pipes, if required, shall incorporate an annular gasket and these gaskets shall cover
    the full face of the flange and shall have holes cut in correspondence to the bolt holes in the
    flanges. Flanges shall be drilled to BS EN 1092 type PN 16. Alternatively jointing system for
    flanged pipes, incorporating rubber rings, may be approved by the Engineer. Stainless steel
    backing rings shall be inserted between the bolt head / nut and the GRP flange to spread the
    load.

    4.3 MDPE AND HDPE PIPELINE JOINTING

    4.3.1 General

    1 The Contractor shall abide by the following guidelines with regards to jointing MDPE and
    HDPE (PE) pipes and fittings unless otherwise approved by the Engineer.

    (a) PE pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever
    possible.

    l .
    (b) PE pipes and fittings of less than 90 mm OD shall be joined together using electro-

    .l.
    fusion couplings and fittings.

    rw
    (c) Electro-fusion fittings may also be used to undertake repairs and install off-takes or
    connections on existing pipelines. They may also be used for the joining together of
    pipe strings where it is not practical to use a butt fusion welding machine.
    (d)
    ta
    To join PE pipes to metal pipes and fittings such as valves, restrained mechanical
    qa
    transition fittings and stub flanges shall be used.
    (e) Restrained mechanical fittings may, with the permission of the Engineer, to undertake
    repairs and install off-takes or connections on existing pipelines.
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    4.3.2 PE Welding Technicians


    se

    1 All PE electro and butt fusion jointing, PE jointing to GRP and metallic valves and fittings shall
    only be undertaken by a certified HDPE Welding Technician holding a valid Welder Licence.
    er

    2 The PE Welding Technician shall have attended a comprehensive course on the Installation
    ov

    and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
    be 5 days and the Technician shall have sat and passed an exam in accordance with the
    GW330 standard of the German Technical and Scientific Association for Gas and Water
    o

    (DVGW) or an equivalent national body approved by the Engineer.


    it
    et

    3 The PE Welding Technician shall hold a valid GW330 Welder License or equivalent issued
    by a national body approved by the Engineer, which shall be subject to annual renewal by
    m

    attending a re-examination course.

    4.3.3 PE Welding Inspectors

    1 A specialist PE Welding Inspector shall observe and supervise the handling, welding, jointing
    to other materials and testing on site of all HDPE pipes and fittings.

    2 The PE Welding Inspector shall have attended a comprehensive course on the Installation
    and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
    be 5 days and the Inspector shall have sat and passed an exam in accordance with the
    GW331 standard of the German Technical and Scientific Association for Gas and Water
    (DVGW) or an equivalent national body approved by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 04: Pipeline Installation

    4.3.4 PE Welding Equipment

    1 All welding machines and welding equipment shall fulfil the requirements of DVS 2208-1 or
    the relevant part of ISO 12176. All welding machines shall be of an automatic or semi-
    automatic design where the welding machine determines and controls the welding
    parameters based on the pipe and fitting details entered by the operator. They shall also be
    equipped with a data logging function that measures and records information listed in DVS
    2208-1.

    2 All machines shall undergo a yearly calibration and function test, carried out by a service
    centre authorised by the machine manufacturer.

    4.3.5 Method Statements

    1 A detailed method statement for PE pipe jointing shall be prepared by the Contractor and
    submitted to the Engineer for approval. The method statement shall include details of which

    .
    equipment shall be used and how the work will be performed to ensure compliance with the

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    .l.
    recommendations of the pipe manufacturer and of this specification. It shall include, but not
    be limited to:

    rw
    (a) Details of the equipment to be employed by the Contractor, together with procedures
    for its operation, maintenance, periodic inspection and testing.
    (b)
    ta
    Details of the experience and certification of the pipe and fitting jointers that shall be
    employed by the Contractor.
    qa
    (c) Procedures for joint preparation, indicating method and degree of cutting, cleaning,
    drying, scraping, alignment, support, etc. of the pipe ends to be joined.
    as

    (d) Jointing procedures, specifying the equipment and tools to be employed, together with
    all relevant parameters such as voltage, temperature, pressure, heating time and
    se

    cooling down time and the means by which jointing operations shall be controlled.
    (e) Inspection and testing procedures together with proposals for the independent and on
    er

    site inspection and testing on welds on a regular basis.


    ov

    (f) QA/QC procedures


    (g) All safety precautions and procedures.
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    4.3.6 Electrofusion Jointing


    it
    et

    1 All electrofusion jointing shall be undertaken in accordance with this specification and the
    guidance given in DVS 2207-1
    m

    2 Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying
    with the requirements of ISO4427, Part 3 shall be used. The electrofusion control unit shall
    incorporate data input through the use of a bar code reader pen and a data retrieval facility to
    allow historical fusion data to be read on the units screen and to be exported to an external
    computer or memory stick.

    3 The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion
    fitting. The power generator shall provide the power requirements of the control box, taking
    into account the electrical characteristics of the control box.

    4 Positioning tools including suitable alignment clamps shall at all times be used to minimise
    misalignment and prevent movement during the fusion and cooling cycle of the joint. A
    suitable shelter shall be used in cold, windy, dusty or wet weather conditions.

    5 Prior to commencing the welding process the Contractor shall measure and ensure that the
    ovality of the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.
    QCS 2014 Section 08: Drainage Works Page 12
    Part 04: Pipeline Installation

    6 All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking
    the pipe scraping, in order to remove any contamination. Prior to scraping the Contractor
    shall measure and mark the area of the pipe or spigot end to be scraped in order to remove
    the oxidized surface to a depth between 0.2 and 0.4 mm. The length of the pipe or spigot end
    to be scraped shall be equivalent to the insertion depth of the electro-fusion joint plus a
    distance of between 10 and 20 mm.

    7 Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip
    or ribbon over the insertion length of the coupler or fitting, shall be used.

    8 Only after preparation and scraping of the pipe end shall the fitting be removed from its
    packaging and immediately inserted over the pipe end.

    9 Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion
    socket.

    .
    10 Alignment clamps shall not be removed before the appropriate cooling time has elapsed.

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    .l.
    Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior
    to commencement of the fusion process.

    rw
    4.3.7 Electro-fusion Joint Inspection

    1
    ta
    All completed electro-fusion joints shall be inspected in accordance with the requirements of
    Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the
    qa
    standard then the electro-fusion fitting shall be cut out and replaced.

    2 After completion of the fusion process, all fusion indicators shall be checked to ensure that
    as

    they are in the position indicated in the Manufacturer's instructions. If any fusion indicators
    are not in the required position the electro-fusion fitting shall be cut out and replaced.
    se

    3 The Contractor shall, on a regular basis allow the Engineer to download the historical data
    relating to the welds made by the unit through the data retrieval facility.
    er
    ov

    4.3.8 Butt Fusion Jointing

    1 All butt fusion jointing shall be undertaken in accordance with this specification, the single low
    o

    pressure jointing procedure given in ISO 21307 and the guidance given in DVS 2207-1.
    it

    2 Assign a unique joint number to each joint and have a data retrieval facility to allow historical
    et

    fusion parameters to be read on the units screen and to be exported to an external computer
    or memory stick
    m

    3 In the case of large diameter pipes having a high wall thickness in excess of 35 mm the
    Contractor may propose to instead follow the single high pressure fusion jointing procedure
    described in ISO 21307. Such a deviation from DVS2207-1 shall only be allowed with the
    written approval of the Engineer.

    4 Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.

    5 A dummy joint shall be made at the start of each welding session using pipe off cuts of the
    same size, material and SDR as the pipe being installed. The normal trimming, bead up and
    full heat soak cycles will be adhered to.

    6 If the pipe size is changed during the day, if the heater plate is allowed to cool below 180C
    or if maintenance of the butt fusion equipment is carried out then a new dummy weld shall be
    performed.
    QCS 2014 Section 08: Drainage Works Page 13
    Part 04: Pipeline Installation

    4.3.9 Butt Fusion Joint Inspection

    1 All butt fusion joints shall be inspected in accordance with the requirements of Appendix B of
    EN 12007 Part 2. Should the joint contain any of the faults described in the standard then the
    joint shall be cut out and replaced. The inspection shall include the following points:

    (a) The gap between the two single beads shall not be below the fusion surface.
    (b) The displacement between the fused pipes must not exceed 10% of the pipe wall
    thickness.
    (c) The difference between two single bead widths shall not exceed 10% of the double
    bead width.
    (d) The weld beads shall be free from all contamination and have a smooth even surface
    with no evidence of distortion, holes or bubbles
    (e) At the direction of the Engineer external beads shall be removed with an approved tool

    .
    and inspected for contamination and defects. They shall also undergo bend back

    l
    testing. Beads should be solid and rounded with a broad root as hollow beads with thin

    .l.
    root and curled appearance can be indicative of excessive pressure or no heat soak.

    rw
    (f) Each removed bead shall be numbered with its corresponding joint number clearly
    displayed and removed beads shall be retained for inspection by the Engineer.
    (g)
    ta
    The width of each external bead width shall be measured using bead gauges and the
    width of the bead shall be within the range given by the pipe and / or welding
    qa
    equipment manufacturer.
    (h) No signs of damage (such as scratches or deep impressions caused by clamps) shall
    be visible on either side of the joint.
    as

    (i) Any joints the do not comply with the above requirements shall be cut out and a new
    joint made; the failed joint shall be handed over to the Engineer.
    se

    (j) Records of all tests and inspections shall be maintained by the Contractor and made
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    available for review and approval by the Engineer.

    4.3.10 Testing of Fusion Joints


    ov

    1 A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under
    o

    laboratory conditions in accordance with ISO 13953 by an approved testing organisation. The
    joints to be tested shall be selected by the Engineer immediately upon completion of the
    it

    welding process, whereupon they shall be cut out and delivered for testing.
    et

    2 A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested under
    m

    laboratory conditions in accordance with ISO 13954 by an approved testing organisation. The
    fittings to be tested shall be selected by the Engineer immediately upon completion of the
    welding process, whereupon they shall be cut out and delivered for testing. They shall
    comprise at least 1 of each type of electro-fusion fitting even if this requires more than 1 % of
    all electro-fusion fittings to be tested. Note that the minimum test requirement is for one fitting
    of each type i.e. bend, coupling, tapping saddle, tee etc. not one of each size and type.

    3 All costs associated with the testing, together with any consequent rectification of faults and
    retesting shall be borne by the contractor.

    4.3.11 Anchorage

    1 Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and tie
    rods used where there is a possibility of pulling the joint under pressure. Concrete thrust
    blocks shall be used in lieu of the above where socket and spigot pipe is used below ground.
    The Contractor shall submit, for the Engineers approval, working drawings and information
    demonstrating the adequacy of anchorage systems other than thrust blocks or other systems
    shown on the Contract Drawings.
    QCS 2014 Section 08: Drainage Works Page 14
    Part 04: Pipeline Installation

    4.4 PIPE LAYING

    4.4.1 General

    1 Except as otherwise specified in this Clause, pipe bedding shall conform with the
    requirements specified in Part 2 of this Section.

    2 The Contractor shall, after excavating the trench and preparing the proper bedding, furnish all
    necessary facilities for properly lowering and placing sections of the pipe in the trench without
    damage and shall properly install the pipe.

    3 Each pipe shall be carefully lowered onto its prepared bed by means of appropriate slings
    and tackle. A recess shall be left in the prepared bed to permit the sling to be withdrawn. If
    the prepared bed is damaged, the pipe shall be raised and the bed made good before pipe
    laying is continued.

    .
    4 No pipe shall be rolled into place for lowering into the trench except over suitable timber

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    .l.
    planking free from roughness likely to damage any coatings.

    rw
    5 The section of pipe shall be fitted together correctly and shall be laid true to line and grade in
    accordance with the bench marks established by the Contractor. The bench marks shall be
    approved by the Engineer.

    6 ta
    The full length of the barrel of the pipe shall have a uniform bearing upon the bedding
    qa
    material and if the pipe has a projecting socket, suitable excavation shall be made to receive
    the socket which shall not bear on the subgrade.
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    7 Pipes shall be laid with the class identification marks or the jointing marks shown by the
    manufacturer in the uppermost position. Pipe sections shall be so laid and fitted together
    se

    that the pipeline will have a smooth and uniform interior. The pipeline shall be clean and
    unobstructed at the time of its installation and shall be true to the required line and levels.
    er

    8 Spigot and socket pipes shall generally be laid upgrade without break from structure to
    ov

    structure and with the socket end upgrade. Backlaying may be permitted as deemed
    necessary and approved by the Engineer.
    o

    9 Whenever work ceases on any pipeline the unfinished end of the pipeline shall be securely
    it

    closed with tight fitting plug or cover.


    et

    10 Before any pipe is lowered into place, the bedding shall be prepared and well compacted so
    m

    that each length of pipe shall have a firm and uniform bearing over the entire length of the
    barrel.

    11 Pipes shall be laid in straight lines, both in the horizontal and vertical planes, between
    manholes or, where directed in the case of pressure pipelines and larger diameter sewers to
    regular curves. The placement of pipes shall comply with the following requirements:

    (a) each pipe shall be plumbed to its correct line and directly and accurately sighted by
    means of a laser positioning system or boning rods and sight rails fixed to secure
    posts which shall be set up and maintained at each end of the sewer to be laid and
    not more than 20 m apart. Sight rails shall be clearly painted in contrasting colours
    and be not less than 150 mm deep, straight and level
    (b) boning rods shall be of robust construction clearly painted and accurately made to the
    various lengths required, the lower end being provided with a flat edged shoe of
    sufficient projection to rest on the invert of the pipes as laid. The boning rod shall be
    complete with a vertical spirit level
    (c) boning rods and sight rails shall not be removed until the pipeline has been checked
    and approved by the Engineer
    QCS 2014 Section 08: Drainage Works Page 15
    Part 04: Pipeline Installation

    (d) alternative methods of locating and levelling pipelines may be allowed subject to the
    approval of the Engineer
    (e) any pipe which is not in true alignment, both vertically and horizontally, or shows any
    undue settlement after laying, shall be taken up and relaid correctly by the Contractor
    (f) all adjustments in line and grade shall be made by scraping away or filling and
    tamping in under the barrel of the pipe and not by wedging or blocking
    (g) the trench shall be kept completely dry
    (h) in no case shall pipes be jointed before being lowered into position
    (i) the gasket should be positioned and lubricated.

    12 Pipelines shall be tested in accordance with Subpart 4.5.

    4.4.2 Laying of Rigid and Semi-Rigid Pipes

    .
    1 Each pipe immediately before being laid shall be carefully brushed out and inspected for

    l
    .l.
    defects. In trench pipes with flexible joints except where concrete bed, bed and surround or
    protection is required shall be laid on a well compacted bed of granular material extending for

    rw
    the full width of the trench and with sufficient material at the sides to permit the pipes to be
    worked into the granular material and firmly supported to true line and level. Sufficient space
    should be left to enable the joints to be made tested and inspected but the Contractor shall

    ta
    ensure that at least three quarters of the pipe length is fully supported. After the pipeline has
    been tested and approved by the Engineer the trench shall be carefully filled to 300 mm
    qa
    above the crown of the pipe with granular material in accordance with the bedding
    requirements specified in Part 2 of this Section and as shown on the Drawings.
    as

    2 Vitrified clay pipes shall be installed in trenches which shall not exceed the maximum trench
    width at 300mm above crown of pipe as shown in Table 2.1 of Part 3 of this Section.
    se

    3 Should the Contractor exceed the trench widths given in Table 2.1 he shall provide
    er

    calculations to show the loading on the pipe and bedding requirements and where required
    he shall provide plain or reinforced concrete cradle or surround, to the approval of the
    ov

    Engineer, at no additional cost. The same type of pipe bedding/surround shall be used for
    the full sewer length between adjacent manholes.
    o

    4 Unless otherwise specified, pipe bedding shall be as shown on the Contract Drawings.
    it

    Notwithstanding the above, for Vitrified Clay pipe the special pipe bedding requirements as
    et

    Table 4.2 are to be provided in all cases whether or not shown on the drawings or indicated
    in the bills of quantity.
    m

    Table 4.2 - Special Bedding Requirements for VC Pipes

    Nominal bore Depth to Invert (D)


    Bedding Type*
    mm m

    700-800 D>9.0 4.1.1.1.1 Plain concrete cradle

    >900 4.0<D<5.0 4.1.1.1.2 Plain concrete cradle


    Reinforced concrete cradle with minimum
    >900 5.0<D<9.0
    0.4% transverse steel
    Reinforced concrete surround with minimum
    >900 D>9.0
    of 1% transverse steel.
    (* as shown on drawings)
    QCS 2014 Section 08: Drainage Works Page 16
    Part 04: Pipeline Installation

    4.4.3 Laying of Flexible MDPE and HDPE Pipes

    1 This clause does not apply to GRP pipes for which laying requirements are given in Clause
    4.3.4 of this Section.

    2 All operations involving the laying, bedding, jointing, backfilling etc. of pipes of plastic
    materials shall be strictly in accordance with the manufacturers recommendations subject to
    the approval of the Engineer.

    3 The pipeline shall be laid on a well compacted sand or granular material that shall extend
    across the full width of the trench bottom. The pipe bed shall have a minimum thickness of
    100 mm and be compacted to a minimum modified Proctor (AASHTO) density of 90% prior
    to the laying of the pipeline.

    4 After laying of the pipeline the Contractor shall place pipe surround material on both sides of
    the pipe, ensuring that no cavities are left between the underside of the pipe and the trench

    .
    bottom or pipe bed. The pipe surround material shall be placed in layers of no more than 150

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    .l.
    mm thick and compacted with hand tools across the width of the trench to achieve a
    minimum Modified Proctor (AASHTO) density of 90%. The pipe surround shall extend to a

    rw
    minimum of 200 mm above the crown of the pipe.

    5 Where pipes are laid in good quality ground conditions such as those native soils comprising

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    granular, sandy or rocky materials, the pipe bed and surround shall comprise clean dry sand
    free from silty and foreign materials and particles of larger than 10 mm diameter.
    qa
    6 The maximum particle size of the granular material shall also not exceed 10% of the pipe
    outside diameter.
    as

    7 Should the excavated native soil fail to meet the above requirements it shall be graded on
    se

    site in order to do so or be replaced with an imported sand or granular material complying


    with the requirements of the UK WIS 4-08-02 or this specification.
    er

    8 Where pipes are laid in poor quality ground conditions such as those native soils comprising
    soft or silty materials, the pipe bed and surround shall comprise an imported granular
    ov

    material complying with one of the grades given in the UK WIS 4-08-02 or this specification.
    o

    9 Single sized aggregate shall not be used for the pipe bed and surround in conditions where
    the native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile
    it

    filter fabric to prevent migration of fine material from the surrounding soil in to the bed and
    et

    surround
    m

    o
    10 When the grade at which the pipeline laid exceeds 10 trench breakers or clay dams shall be
    installed to prevent the migration of bed and surround material due to the flow of water along
    the trench.

    4.4.4 Laying of GRP Pipes

    1 During the mobilisation period the Contractor shall submit for the Engineers approval the
    pipe manufacturers complete and detailed specification for the handling and installation of
    pipe and fittings in open trench and such other methods of construction of pipeline specified
    or proposed by the Contractor. This specification shall be submitted during the mobilisation
    period irrespective of whether the data was submitted with the Tender.

    2 The Contractor shall transport, store, handle and lay pipes in accordance with the approved
    manufacturers handling and installation specification as approved by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 17
    Part 04: Pipeline Installation

    3 The manufacturers handling and installation specification shall include details of the
    manufacturers technical expert to be assigned to the Contract. The technical expert shall
    have extensive experience of handling and installation of GRP and shall be fully familiar with
    the manufacturers handling and installation specification.

    4 The manufacturers technical expert shall provide comprehensive technical assistance to the
    Contractor throughout the Contract and shall regularly monitor the Contractors handling and
    installation operations.

    5 Any instructions or advice given by the manufacturers technical expert to the Contract shall
    be copied to the Engineer. In the event that the Contractor deviates from the approved
    handling and installation specification, the manufacturers technical expert shall immediately
    inform the Contractor and the Engineer.

    6 All costs associated with the provision of a technical expert by the manufacturer shall be
    borne by the Contractor.

    l .
    .l.
    7 GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding
    material. The space below the barrel of the pipes shall be filled with special bedding material

    rw
    to the full width of the trench in layers not exceeding 150 mm in thickness. After pipe laying,
    further special bedding shall be placed and thoroughly compacted to fill the entire space
    between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the

    ta
    top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe
    qa
    shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater
    thickness of special bedding below, around and over the pipes than those specified they shall
    be deemed to have been allowed for in the rates for bedding.
    as

    8 Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first
    se

    100 mm of pipe at entry to the structure shall be surrounded by an approved flexible material.
    Flexible joints shall be incorporated adjacent to structures, in accordance with Clause 4.2.4.
    er

    9 Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed
    ov

    with two layers of resin, the second layer being paraffin wax filled to ensure full cure.

    10 Where GRP pipes are required to be surrounded with concrete, all necessary precautions
    o

    shall be taken to ensure that maximum allowable deflections are not exceeded. Adequate
    precautions are to be taken to ensure that the pipe does not float during placing of the
    it

    concrete surround.
    et

    11 At all times, backfilling shall be carefully carried out to ensure no voids or pockets of
    m

    unconsolidated material are present. The Contractor shall monitor the vertical deflection of
    the pipes throughout the backfilling operation. No pipe shall exhibit more than 1.5% deflection
    after placing and compaction of the granular bed and surround. In addition, after completion
    of the trench backfilling, the average deflection of a length of pipe shall not exceed 1.5%, and
    every pipe shall be demonstrated to exhibit no more than the manufactures calculated
    allowable Initial Deflection, or 3.5% deflection, whichever is smaller. If any of these values
    are exceeded, the affected pipes shall be exhumed and re-laid.

    12 The deflection shall also be checked on each length between manholes or chambers before
    commissioning to determine whether longer term deflections are within permissible limits.
    The average deflection of a length of pipe shall not exceed 3%, and every pipe shall be
    shown to exhibit a deflection no greater than 5%, or the calculated allowable deflection
    consistent with the achievement of a long term deflection not exceeding 5%, whichever is
    smaller, at any point. Pipes exhibiting greater deflections shall be exhumed and re-laid.

    13 Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated allowable long term
    deflection, shall be exhumed, indelibly marked REJECTED, removed from the site and not
    reused.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 04: Pipeline Installation

    4.4.5 Corrosion Protection of Ferrous Pipelines

    1 Where tape wrapping is wrapped at site it shall be applied by machine under factory
    controlled conditions in accordance with Clause 3.7.6 of this Part.

    2 Pipe joints shall be protected by continuing the tape wrapping, or by heat shrink polyethylene
    tubes coated internally with thermoplastic adhesive. The profile of the pipe joint shall be
    smoothed using bituminous mastic or preformed plastic foam sections taped in position.
    Heat shrink sleeves shall be on pipes with extruded polythene coatings, and in all cases shall
    be applied in accordance with the sleeve manufacturers and pipe coating manufacturers
    instructions.

    3 Joints within in-situ concrete chambers do not require heat shrinkable sleeve protection.

    4 Damaged areas of protective coating or wrapping shall be repaired in a manner to be


    approved by the Engineers Representative.

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    .l.
    5 Ferrous pipelines shall be supplied with one of the following corrosion protection systems:

    rw
    (a) Cold applied self-adhesive laminate tape wrapping
    (b) Extruded polyethylene coating
    (c) Loose polyethylene coating
    ta
    qa
    6 Extruded polyethylene coating shall be as Clause 3.7.7. Heat shrink sleeves shall be used
    over joints in polyethylene coated buried pipes.
    as

    7 Spigot ends of pipes coated in either of the approved manners shall not be coated over the
    depth of engagement within the socket or flexible coupling, but shall be coated with epoxy,
    polyethylene or polyurethane for pipes internally lined with these materials.
    se

    8 Where ductile iron buried pipe is designated to be encased in loose polythene sleeving,
    er

    installation shall be in accordance with BS 6076.


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    9 The pipe shall be supported by a central sling and a length of sleeving pulled over the spigot
    end and bunched up to the sling.
    o

    10 The pipe shall then be rested on blocks placed at its extremities and the sleeving pulled up to
    it

    the socket and folded and taped or tied in position. The sling shall then be replaced to
    et

    enable jointing to be carried out. A wide sling shall be used to distribute the weight and thus
    obviate intense pressure on the sleeving. Care shall be taken to avoid damage when
    m

    removing the sling from the trench.

    11 The sleeve shall not be drawn up over the pipe joints until the completion of the hydrostatic
    testing. Immediately after making the pipe joint, the pipe trench shall be backfilled as
    described hereinbefore in readiness for the hydraulic testing and to prevent damage to the
    sleeving.

    12 After completion of the hydraulic testing, the sleeving shall be drawn up over and fixed
    around the pipe joints. A pad of sleeving shall first be placed around the joint to prevent
    damage to the joint sleeve by the edges of the socket or by bolts. A length of sleeving shall
    then be drawn over joint overlapping itself either side of the joint for a minimum of 300 mm
    and this shall be tied or taped tightly in position.

    13 Any pipe sleeving perforated during fitting shall be repaired by overlaying with a short sleeve
    folded and secured with tape. Torn or damaged sleeving which is considered by the Engineer
    as not repairable by this method shall be replaced by the Contractor.
    QCS 2014 Section 08: Drainage Works Page 19
    Part 04: Pipeline Installation

    14 Immediately after fitting the pipe sleeving the pipe trench shall be partly backfilled to prevent
    damage to the sleeving.

    4.4.6 Concrete Protection to Pipe

    1 Where concrete protection to pipelines is specified or ordered by the Engineers


    Representative a 75 mm thick Grade 20 concrete layer shall be laid over the full width of the
    trench and never less than 150mm wider on each side than the barrel of the pipe and with its
    top surface positioned as shown on the drawings.

    2 This concrete shall be allowed to set and be thoroughly washed down before pipe laying is
    started.

    3 The length of pipeline laid in any one operation before concreting the pipeline shall be that
    which in the opinion of the Engineers Representative permits accurate laying of the pipeline
    and proper compaction of the fill.

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    .l.
    4 Pipes up to 1200mm diameter shall be firmly supported on precast concrete blocks and
    separated from them by 25mm thick saturated softwood packing.

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    5 Pipes greater than 1200mm diameter shall be firmly supported on precast concrete blocks
    and separated from them by saturated softwood packing 38mm thick.

    6 ta
    Alternatively for pipes up to 300mm diameter a layer of concrete Grade 20 of minimum water
    qa
    content can be laid on the 75mm concrete layer and the pipes worked into this concrete to
    true line and level before it sets. Sufficient space shall be left to enable joints to be made,
    tested and inspected but the Contractor shall ensure that the barrel of the pipe is fully
    as

    supported for at least two thirds of the pipe length.


    se

    7 After the pipeline has been tested, and approved by the Engineers Representative, the
    concrete shall be thoroughly washed down and additional concrete Grade 20 shall be
    carefully placed and compacted thereon to avoid disturbing the pipes or joints until the
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    appropriate profile for the type of protection required has been reached.
    ov

    Minimum thickness of
    Nominal bore of pipe
    surround
    mm
    o

    mm
    it

    Up to and including 500 150


    et

    500 900 250


    m

    1000 1100 300


    1200 - 1400 350
    >1400 400

    8 Concrete protection to the pipelines shall be concrete cradle or concrete surround as detailed
    on the Drawings and shall be of concrete Grade 20. The thickness of the concrete surround
    below, to the sides and above pipes shall be as follows:

    9 When support of excavation is provided building paper shall be placed against that support
    before concreting to facilitate withdrawal of support.

    10 In the case of spigot and socket pipes with flexible joints the concrete protection at each joint
    shall be interrupted in a vertical plane at the edge of the socket by a strip of fibreboard or
    other material approved by the Engineers Representative and of the following thickness:
    Up to 300mm nominal bore - 13mm
    QCS 2014 Section 08: Drainage Works Page 20
    Part 04: Pipeline Installation

    Over 300 and up to 600mm nominal bore - 25mm


    Over 600 and up to 1200mm nominal bore - 38mm
    Over1200 and up to 2000mm nominal bore - 50mm

    11 The protection and filling of headings shall be of mass concrete Grade 20 and may be carried
    out in one operation.

    4.4.7 Deflection Criteria for Flexible Pipelines

    1 All flexible pipelines will be subjected to deflection measurements at Site. Sections of pipe
    failing to meet the specified deflection criteria shall be removed from the trench and relaid,
    provided the pipe is not damaged. This procedure shall be repeated until the pipeline is
    found to be satisfactory. Removal from the trench and relaying shall be an obligation of the
    Contractor. If the permanent set or deflection, after removal, exceeds the limits set out
    below, the pipes shall be deemed to be damaged and will therefore be condemned. Pipes so

    .
    condemned shall be indelibly marked, removed from the Site, and replaced by the

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    .l.
    Contractor.

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    2 At all times, backfilling shall be carefully carried out to ensure that no voids or pockets of
    unconsolidated material are present. The Contractor shall monitor the vertical deflection of
    the pipes throughout the backfilling operation. No pipe shall exhibit more than 3.0 %

    ta
    deflection after placing and compaction of the granular bed and surround. In addition, after
    completion of trench backfilling, the average deflection of a length of pipes shall not exceed
    qa
    3.0 %, and every pipe shall be demonstrated to exhibit no more than the manufacturers
    calculated allowable initial deflection, or 5.0 % deflection, whichever is the smaller. If any of
    these values is exceeded, the affected pipes shall be dismantled and relaid.
    as

    3 MDPE and HDPE (PE) pipes may be bent or curved on site down to a minimum radius as
    se

    recommended by the manufacturer. In the event of the manufacturer providing no


    recommendation, the minimum bend radius shall not be less than 25 times the pipe OD,
    Where there are space restrictions the bend radius may be reduced down to 20 times the
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    pipe OD, but only with the written permission of the Engineer.
    ov

    4 No electro-fusion or mechanical joints should be incorporated in the sections of PE pipework


    which are to be bent. Instead a formed bend or elbow should be welded in the pipeline in
    order to prevent excessive stress.
    it o

    5 The deflection shall also be checked on each length between manholes before
    et

    commissioning to determine whether longer-term deflections are within the specified limits.
    The average deflection of a length of pipes shall not exceed 3 %, and every pipe shall be
    m

    shown to exhibit a deflection no greater than 5 %, whichever is the smaller, at any point.
    Pipes exhibiting greater deflections shall be exhumed and relaid.

    6 Pipes exhibiting a deflection greater than 8 % or 1.6 times the calculated allowable long term
    deflection, shall be exhumed, indelibly marked REJECTED, removed from site and not
    reused.

    4.4.8 Backfilling

    1 The requirements of Part 2 of this Section shall apply, except as otherwise specified in this
    Clause.

    2 After the pipeline has been tested and approved by the Engineer, the trench shall be carefully
    backfilled to 300 mm above the crown of the pipe for rigid pipes with granular material.
    Backfilling of the pipe trench should be carried out as designated, or shown on the Contract
    Drawings.
    QCS 2014 Section 08: Drainage Works Page 21
    Part 04: Pipeline Installation

    3 Where concrete bedding or surround is required, the backfill shall not be placed before the
    compressive strength of the site concrete has reached 15 MPa.

    4 Where concreting to pipeline is specified, a blinding layer of Grade 20 SRC concrete shall be
    placed over the full width of the trench or heading.

    5 Pipes to be bedded on or cradled with concrete shall be supported on precast concrete


    setting blocks, the top face of each block being covered with a separation layer.

    6 Concreting to the pipeline shall be either bed or bed and surround as shown on the Drawings
    and shall be of Grade 20 SRC concrete along such lengths as are shown on the Drawings or
    ordered by the Engineer.

    7 The pipe shall be prevented from moving during concreting.

    8 Where concrete bed and surround is used with GRP and PVC-U pipes the maximum spacing

    l .
    between pipe joints shall be 3 m. For other pipe materials the maximum spacing shall be as

    .l.
    directed by the Engineer.

    rw
    9 When support of excavations is provided, building paper shall be placed against that support
    before concreting to facilitate withdrawal of the support. Building paper shall comply with BS
    1521 Class A2.
    ta
    qa
    10 In the case of pipes with flexible joints, the concrete at each joint shall be interrupted in a
    vertical plane at the edge of the socket by a strip of fibreboard or other material approved by
    the Engineer and of the following thicknesses:
    as

    Up to 300 mm nominal bore - 13 mm


    Over 300 mm and up to 600 mm nominal bore - 25 mm
    se

    Over 600 mm and up to 1200 mm nominal bore - 38 mm


    er

    Over 1200 mm and up to 2000 mm nominal bore - 50 mm


    ov

    11 The protection and filling of headings shall be of Grade 20 SRC concrete.

    12 Where concrete slab protection to GRP and PVC-U pipelines is required such protection
    o

    shall extend a minimum of 200 mm either side of the pipe trench. The slab shall be of
    it

    reinforced concrete as shown on the Drawings.


    et

    4.4.9 Deflection at Joints


    m

    1 Where the Engineer orders or allows a change of direction to deflect pressure pipelines from
    a straight line, either in the vertical or horizontal planes to avoid obstruction or where long
    radius curves are permitted, the amount of deflection allowed shall not exceed that required
    for satisfactory connection of the joint and shall be approved by the Engineer. Where a
    change of direction cannot be made by deflection at the joints of ordinary straight pipes,
    bends shall be used. The locations of such bends and other specials are shown on the
    Contract Drawings and their exact positions will be determined by the Engineer on the Site.

    4.4.10 Wadi Crossings

    1 Work at any crossing of a wadi or other waterway shall be carried out as expeditiously as
    possible to the satisfaction of the Engineer and any responsible Government agency or other
    authority, with minimum interference to the free flow of water. Details of any temporary works
    which may affect the flow of the wadi shall be submitted to the Engineer at least 14 days
    before starting work.
    QCS 2014 Section 08: Drainage Works Page 22
    Part 04: Pipeline Installation

    2 Where pipelines passes underneath a wadi, ditch, open surface water channel, or other
    waterway, the pipelines shall be encased in concrete. The minimum thickness of encasement
    shall be 150 mm. Unless otherwise designated, the depth of cover shall not be less than 600
    mm from the bed of the water coarse to the top of the concrete.

    3 The Contractor shall fill the trench in both banks with rock fill or concrete up to the designated
    levels. The extent of this work may be varied to suit each individual crossing. Unless
    otherwise ordered, the concrete encasement of the pipe shall extend at least to a section
    vertically below the tops of the banks. Protection against erosion to the banks shall be
    provided by means of stone pitching or riprap.

    4.4.11 Pipe Supports

    1 Pipe hangers and saddle supports shall be of standard manufacture as shown on the
    Drawings and in compliance with the following general requirements:

    .
    (a) piping shall be supported independently from appurtenances to which it is affixed.

    l
    .l.
    (b) all weight of piping and contained fluids shall be transferred to a structures or
    foundation system through stools, brackets, pipe saddle supports, or overhead hanger

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    systems.
    (c) a support shall be provided for each pipe at or near the point where it is connected to

    (d) ta
    machinery or valves. A support shall be provided for each valve and special fitting.
    flexible joints shall be required at either ends of the support system.
    qa
    (e) where necessary, expansion joints shall also be provided.
    (f) pipe hangers and supports shall generally be fabricated in Mild Steel. These shall be
    as

    galvanised and painted with coal tar epoxy.


    se

    2 For pipelines to be fixed in culverts, the Contractor shall prepare proposals for thrust and
    anchor support and submit them to the Engineer for approval. Such approval shall not relieve
    the Contractor from his responsibility for the adequacy of his proposal. Additional
    er

    requirements for both location and details of supports may be shown on the Drawings or
    directed by the Engineer as the work proceeds to suit the actual conditions encountered.
    ov

    4.4.12 Building-in Pipes to Structures


    o

    1 Pipes constructed into a concrete wall or structure shall be protected with a concrete
    it

    surround integral with the external face of the structure as shown on the Drawings.
    et

    2 All internal and external protection membranes to the concrete shall be sealed around the
    m

    pipe openings as recommended by the membrane manufacturer. When the pipe is later
    fixed, the remaining hole shall be re-formed and filled with non-shrink grout.

    3 Any over-excavation adjacent to a structure or beneath the formation level of a pipeline,


    either to be constructed under the Contract or in a future contract, shall be backfilled with
    Grade 20 SRC concrete.

    4 Pipes and pipe specials through concrete walls and floors shall as far as possible be
    positioned and built in during construction. They shall be located exactly in the positions
    shown in the Contract Drawings and shall be true to line and level. The Contractor shall take
    particular care to ensure that fully compacted concrete is in contact with the pipe at all points.
    QCS 2014 Section 08: Drainage Works Page 23
    Part 04: Pipeline Installation

    5 Where it is impracticable to cast pipes and specials in the concrete, boxouts shall be
    provided in the formwork. The box shall have six or eight sides, depending on the pipe
    diameter, and shall be no larger in size than will give adequate clearance for the subsequent
    positioning and grouting in of the pipe. The sides of the boxout shall be provided with a
    tapered central annular recess to provide a positive key. The boxout shall be provided with a
    grout hole and, at the top of the central annular recess a vent hole. The boxhole shall be
    stripped with the main formwork and the concrete surface thoroughly cleaned and
    roughened.

    6 Unless otherwise shown on the Contract Drawings, where pipes pass through a concrete wall
    or structure they shall be protected with a surround of Grade 20 SRC concrete integral with
    the external face of the structure. For pipes of less than 500 mm diameter, the surround shall
    extend from the wall or structure by 300 mm and the width and depth of the surround beyond
    the outside face of the pipe at its horizontal and vertical diameters shall be a minimum of
    300 mm or as otherwise indicated on the Drawings. For pipes of 500 mm diameter or greater

    .
    the surround shall extend from the wall or structure by 500 mm and the width and depth of

    l
    .l.
    the surround beyond the outside face of the pipe at its horizontal and vertical diameters shall
    be 500 mm or as otherwise indicated on the Drawings.

    rw
    7 On socket and spigot pipelines except those of GRP or other plastic materials the socket end

    ta
    of the pipe passing through the wall shall be flush with the outside face of the concrete
    surround. On socket of spigot pipelines of GRP or other plastic materials the socket end of
    qa
    the pipe passing through the wall shall protrude 300 mm from the concrete surround. A
    protective synthetic rubber strip 6 mm thick and 150 mm wide shall be provided around the
    pipe at the limit of the concrete surround as shown on the Contract Drawings.
    as

    8 On all other flexibly jointed pipes the plain end of the pipe shall protrude from the concrete
    se

    surround by a maximum of 300 mm or that distance required to properly make the joint.
    er

    9 The first pipe that is clear of concrete surround beyond the external face of a concrete wall or
    structure shall be a short length of either spigot and socket or double spigot to suit the flow
    ov

    direction and pipe material. The effective length of this pipe shall be 1.5 times the nominal
    bore or 600 mm whichever is the greater.
    o

    10 For mechanically jointed pipes the plain end shall protrude from the surround by a maximum
    it

    of 300 mm or that distance required to make a proper joint.


    et

    11 Where the structure is tanked, Grade 20 OPC concrete shall be used and the tanking shall
    m

    extend to the concrete surround.

    4.4.13 Cleanliness of Pipelines

    1 Pipelines and manholes shall at all times be kept free of all silt, mortar, debris and other
    obstructions. When work is not in progress the open ends of the pipeline shall be securely
    plugged with an approved watertight plug or stopper firmly fixed to resist unauthorised
    removal. Claw type plugs or any type liable to damage the pipe shall not be used. All such
    stoppers, plugs or caps shall be provided with a vent incorporating a valve for the purpose of
    testing whether the pipeline is under pressure or vacuum and to enable pressures to be
    equalised before its removal.

    2 The Contractor shall clear the inside of each fitting and pipe length immediately before
    jointing and shall swab all fittings and pipe lengths to remove all dirt, sand or other matter that
    may clog the pipeline or contaminate the fluid to be transported in the pipeline. After jointing,
    the interior of the pipes shall be freed from any dirt, stones or other matter that may have
    entered them. For this purpose, a rubber disc, brush, or other suitable implement that will not
    harm the internal lining of the pipe shall be pulled through the pipe after jointing.
    QCS 2014 Section 08: Drainage Works Page 24
    Part 04: Pipeline Installation

    3 Pressure pipelines and treated sewage effluent pipelines shall be flushed and a swab passed
    through. Large diameter pipelines shall be visually inspected internally to the approval of
    Engineer.

    4.4.14 Marker Tape

    1 All trenches for pressure pipelines, shall be marked with a high quality acid and alkali-
    resistant red non bio-degradable plastic tape with a minimum width of 150 mm placed during
    backfilling 300 mm below finished surface or as directed by the Engineer. These tapes shall
    2 2
    have a minimum strength of 125 kg/cm in the longitudinal direction and 105 kg/cm
    transversely with an elongation factor in the longitudinal direction of 350 percent. The text on
    the tape shall be permanent black ink bonded to resist prolonged chemical attack by
    corrosive acids and alkaline with message repeated at a maximum interval of two metres.
    Tapes over non-ferrous pipes shall be detectable by electro-magnetic means using low
    output generator equipment.

    l .
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    2 The tape wording and colour shall be as follows:
    WORDING COLOUR

    rw
    DANGER : FOUL SEWAGE RED
    CAUTION TREATED SEWAGE EFFLUENT GREEN
    SURFACE WATER ta GREY
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    WATER MAIN BLUE
    DANGER : FUEL PIPELINE BROWN
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    3 The tape shall be laid continuous over pipelines and at joints there shall be a minimum of one
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    metre overlapping. Tape shall be terminated inside valve boxes to allow clipping of detector
    equipment to the tape.
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    4.4.15 Pressure Pipeline Marker Posts


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    1 Pipeline marker posts shall be provided at all points where the pipeline crosses boundaries
    or changes direction and elsewhere at maximum intervals of 100m. Each marker post shall
    o

    be set over the centreline of the pipelines with concrete Grade 20 SRC concrete base
    surround in accordance with the Contract Drawings. Marker posts shall incorporate a
    it

    description of the pipeline and its service in Arabic and English to the approval of the
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    Engineer. Offset marker posts may also be used in areas where the post could not be
    installed over the centreline of the pipelines.
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    2 Coloured marker plates shall be made from multi-layered plastic, green for TSE and orange
    for foul sewage.

    4.4.16 Valve Chamber Marker Posts

    1 Valve chamber marker posts shall be installed at all chambers, indicating the type of
    chamber, its reference number and distance from the marker post in Arabic and English to
    the approval of the Engineer.

    2 Where the pipeline is in a footpath or verge, the marker post shall be installed against the
    wall or property boundary and facing the chamber cover, with Grade 20 SRC concrete base
    surround.

    4.4.17 Abandonment of Pipelines

    1 Pipelines and service connections to be abandoned shall first be emptied completely.


    QCS 2014 Section 08: Drainage Works Page 25
    Part 04: Pipeline Installation

    2 Pipelines and service connections to be abandoned shall be filled completely with a cement
    slurry or concrete using a grout pan or an alternative method approved by the Engineer such
    that the discharge slurry or concrete can be forced into the pipeline under pressure.

    3 The Contractor shall ensure that all existing connections to the sewer to be abandoned have
    been plugged or disconnected before beginning filling.

    4 The Contractor shall inform the Engineer of his intention to begin this operation and shall
    obtain the Engineers approval in writing for the abandonment of each particular length before
    beginning filling.

    5 Upon completion of the above procedure, the Contractor shall undertake abandonment of
    manholes inspection chambers and other structures. Where a pipeline or service connection
    to be abandoned connects into a manhole or chamber to be retained, the connection shall be
    plugged at the chamber wall and the associated channel in the benching of the manhole or
    chamber shall be cleaned and filled with concrete Grade 20 SRC. The benching shall then

    .
    be covered with the appropriate protective lining to match the existing manhole lining.

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    6 Unless otherwise designated, existing pressure pipelines to be abandoned shall be emptied

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    and sealed at each end of the pipeline with a removable expanding stopper to the Engineers
    approval. The stopper shall include a valve for the purpose of venting and for the equalising
    internal and external pressures removal. Any chambers located along the pipeline to be

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    abandoned shall be demolished and the pipeline ends sealed as specified.
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    4.4.18 Abandonment of Structures

    1 Where manholes, septic tanks, cesspits, soakpits and other structures are to be abandoned,
    as

    they shall be emptied of their contents to the approval of the Engineer. The contents
    including sludge from these structures, whether undiluted or mixed with sand, shall be
    se

    disposed of off the Site by the Contractor to a location approved by the Engineer. The
    Contractor shall submit in writing his proposals for emptying the contents and disposal. No
    work shall begin on demolition until the structure has been completely emptied.
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    2 After desludging, the roof slabs and tops of walls of the structure shall be demolished to an
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    elevation not less than 500 mm below existing ground level. The fragments of demolished
    structures may be used to partially fill the void. Voids shall be filled up with sand, watered and
    o

    well compacted up to the elevation of the underside of the cover slab. The frames and
    it

    covers of manholes and chambers shall be removed by the Contractor and delivered to the
    designated Employers stores and placed into storage.
    et
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    3 If an existing service is found within a structure to be abandoned, the Contractor shall inform
    the Engineer and carry out the Engineers instructions for ensuring that the service pipeline is
    retained or restored. If a sleeve is to be provided, the sleeve shall extend for 100 mm on
    either side of the structure. When backfilling or working around an existing service or sleeve,
    the Contractor shall take all precautions to ensure that no damage occurs and that there is
    no interruption of service.

    4.4.19 Corrosion Protection of Flexible Couplings and Ferrous Fittings

    1 Buried flexible couplings, including flange adaptors shall be protected as follows:

    (a) Mastic paste filling (Denso paste or similar)


    (b) Mastic tape wrapping (Denso tape or similar)
    (c) and finished with cold applied self-adhesive laminate tape wrapping (or heat shrink
    sleeving) in accordance with Clause 8.4.3.5

    2 Couplings, including all associated nuts and bolts, within chambers or pumping stations shall
    be polyamide powder coated (Rilsan or similar).
    QCS 2014 Section 08: Drainage Works Page 26
    Part 04: Pipeline Installation

    4.5 PIPELINE STRUCTURES AND APPURTENANCES

    4.5.1 Manholes for Foul Sewerage

    1 The Contractor shall prepare a standard record sheet for every manhole and structure and
    shall submit to the Engineer for information only.

    2 Manholes shall be constructed as shown on the Contract Drawings and at the locations
    indicated thereon or at other locations directed by the Engineer.

    3 The blinding concrete shall be mass concrete Grade 25 SRC concrete and the manhole base
    slab, benching and insitu concrete walls shall be Grade C40 SRC concrete.

    4 Precast concrete manhole rings shall be manufactured using Grade C50 SRC concrete. The
    joint surfaces and outer face of the precast concrete rings shall have factory applied epoxy
    coating in accordance with Part 8 Clause 8.3.15. The inner face of the precast manhole ring

    .
    shall be a prefabricated GRP liner at least 6mm thick bonded by lugs to the concrete. The

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    completed joints between precast concrete rings shall have an insitu applied sealing strip at
    least 6mm thick overlapping the GRP liner by a minimum of 150mm each side. The sealing

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    strip shall be capable of withstanding the full hydrostatic head of external ground water to
    ground level and the maximum internal hydrostatic head, whichever is the greater.

    5
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    The underside of the base and the external faces of insitu concrete bases and walls shall be
    protected with a membrane tanking system. The necessary period for setting, as
    qa
    recommended by the manufacturer, shall be allowed before beginning other works to
    complete the construction of the manhole.
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    6 The cover slab shall be surmounted by ductile-iron manhole cover and frame of the quality
    specified. The covers in road and paved areas shall be accurately set on precast concrete
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    segments to the level and slopes of the roads or pavements.


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    7 In the case of shallow manholes, the cover and frame may be cast directly monolithic with the
    reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract
    ov

    Drawings.

    8 The interior face of manholes and access shafts shall be prefabricated GRP liners at least
    o

    6 mm thick permanent lining.


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    et

    9 Prefabricated GRP benchings and channels shall be preformed, inverted and filled with
    Grade C40 SRC concrete. Alternatively, the GRP lining may be applied to the in-situ
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    concrete benching after constructing the benching.

    10 GRP lining to walls shall incorporate lugs moulded onto the outside face at 500 mm centres
    to allow bonding to the concrete surround. The lining shall have adequate strength to
    withstand handling, and shall not buckle or distort during pouring of the concrete surround.
    Internal bracing may be used during pouring of the concrete surround. Internal bracing may
    be used during pouring to maintain circularity and verticality.

    11 Cover slabs shall be precast using Grade C50 SRC concrete and shall incorporate a
    preformed flat sheet of GRP on the soffit, bonded to a GRP tube to form the access opening.
    Both linings shall incorporate lugs moulded onto the surface to allow bonding to the concrete.
    The overall size of the lining to the soffit of the slab shall be 150mm greater than the internal
    diameter of the manhole onto which the slab is to be placed.
    QCS 2014 Section 08: Drainage Works Page 27
    Part 04: Pipeline Installation

    12 In all cases, the outer surface of the GRP, exposed to the sewage atmosphere, shall consist
    of a chemically resistant layer comprising vinyl ester resin suitably reinforced with a C glass
    or synthetic tissue veil. This layer shall be no less than 2mm thick, and shall have a resin
    content by weight of approximately 90% at the exposed surface, reducing to 65% - 75% at
    the inner surface. The remainder of the liner shall consist of vinyl ester or isophthalic resins
    and E or ECR glass chopped strand mat. Fillers, such as silica sand and calcium
    carbonate shall not be used. Loss of Ignition Test to BS 2782 (method 1002) shall be
    conducted on random samples of GRP manhole liner to detect percentage of glass and the
    presence of any silica sand filler.

    13 Joints in the lining tubes of insitu concrete manholes shall not normally be permitted.

    14 Joints between preformed GRP benchings and lining tubes shall be made using an external
    sleeve 200 mm long bonded onto both units, and then bandaged using suitable resin and
    chopped strand mat prior to casting the insitu concrete walls. Such bandaging shall extend
    75 mm either side of the edge of the sleeve. On the inside face of the manhole, the joint

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    between the benching and liner tube shall be filled with vinyl ester paste to produce a smooth

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    finish.

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    15 If GRP linings to benchings are to be formed in situ the surface of the wall lining tube shall be
    lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius shall

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    then be formed of vinyl ester paste at the junction of benching and wall. The GRP lining to
    the channels and benchings shall then be built up by applying isophthalic or vinyl ester resin
    qa
    to the whole of the benching, fillet and abraded wall lining. A layer of E or ECR mat shall
    than be rolled into the resin using a suitable steel roller to exclude all air and provide
    complete immersion of the glass fibre in the resin. After a period to allow pre-gel to a tacky
    as

    state a second coat of resin shall be applied followed by a further layer of glass fibre mat.
    This process shall be repeated until the total thickness of lining is approximately 4 mm. Vinyl
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    ester resin and C glass or synthetic tissue veil shall then be used to complete the lining.

    16 Top surfaces of benchings shall incorporate silica sand to form a non-slip surface.
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    17 The precast cover slab shall be seated on the walls using sand/cement mortar. The joint
    shall be raked out 15 mm deep on the inside face and pointed with an approved pitch
    extended polyurethane sealant.
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    18 Ladders in structures where shown on the drawings shall be fabricated in stainless steel
    et

    Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
    stainless steel.
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    19 Intermediate the Contractor shall provide the Engineer with a 10 year unconditional
    guarantee against failure of all GRP linings whether caused by defective materials or
    workmanship. The guarantee shall be valid from the date of completion of the installation
    and must be handed to the Engineer before the issue of the Final Completion Certificate.

    20 All manholes shall be watertight on completion and where leakage is discovered the
    Contractor shall perform such work and provide all materials as are necessary to render such
    faulty work watertight. The Contractor is warned that he should expect rubbish and debris to
    be deposited in the manholes during the course of construction and he should take the
    necessary measures to ensure that the manholes clean.

    21 Backfilling around manholes in roads shall be carried out using granular material as
    approved by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 28
    Part 04: Pipeline Installation

    4.5.2 Manholes for Surface Water Sewerage

    1 Bases and mass concrete manholes shall be cast using Grade 40 SRC concrete. Where
    reinforced concrete manholes are specified they shall be constructed in accordance with the
    drawings and have a GRP liner complying to Clause 4.4.1. The GRP liner shall extend to
    300mm above the soffit of the outlet pipe of the manhole. The inner surface above the GRP
    liner shall have an epoxy protective coating.

    2 The benching and channels shall be GRP lined as Clause 4.4.1.

    3 The underside of the base and the sides of insitu concrete bases and walls shall be protected
    with a membrane tanking system as Clause 4.4.1.

    4 Precast Grade C50 SRC concrete manhole rings may be used above the level of the GRP
    inner liner. The precast rings shall have a factory applied epoxy protective coating to all
    surfaces.

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    5 Cover slabs shall be precast using Grade 50 SRC concrete and shall have a factory applied
    epoxy coating to all surfaces.

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    6 The Contractor shall provide the Engineer with a 10 year unconditional guarantee against
    failure of all GRP linings whether caused by defective materials or workmanship. The

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    guarantee shall be valid from the date of completion of the installation and must be handed
    over to the Engineer before the issue of the Final Completion Certificate.
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    7 Ladders in structures where shown on the drawings shall be fabricated in stainless steel
    Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
    as

    stainless steel.
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    4.5.3 Chambers
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    1 The Contractor shall prepare a standard record sheet for every chamber for valves, meters,
    inspection, washouts and other similar purposes for the approval of the Engineer.
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    2 Chambers shall be constructed in accordance with the Contract Drawings and at the
    locations or at other locations directed by the Engineer.
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    3 The Contractor shall ensure that there is a minimum clearance of 300mm around all flanges
    it

    and parts of valves built into chambers, including the handwheel.


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    4.5.4 Connections to Existing Pipelines

    1 At locations shown on the Contract Drawings or as instructed by the Engineer, the Contractor
    shall connect the new pipelines to the existing pipelines or structures but not until the said
    pipelines have passed the final tests.

    2 The Contractor shall co-ordinate with Drainage Affairs, Maintenance Department staff to
    make connections onto existing foul sewers and other drainage pipelines.

    3 The Contractor shall be responsible for dealing with all flows while making connections to
    existing sewers or drainage pipework by over-pumping the entire flow between manholes or
    other approved bypassing methods. The Contractor shall retain a standby pump and fulltime
    operator on site during pumping operations.
    QCS 2014 Section 08: Drainage Works Page 29
    Part 04: Pipeline Installation

    4.5.5 Anchor and Thrust Blocks

    1 The Contractor shall construct anchor and thrust blocks at every bend and junction on
    pressure pipelines and where otherwise shown on the Contract Drawings or instructed by the
    Engineer. Each thrust block shall to have a sufficient bearing area and shall be placed to
    safely transmit thrust to the surrounding original ground. If soft, spongy, unstable or similar
    material is encountered upon which the thrust block is to bear this unsuitable material shall
    be removed and replaced with Grade 20 SRC mass concrete as directed by the Engineer.

    2 The excavation for the thrust block shall be carried out prior to laying the pipes except that a
    trimming margin of not less than 150mm shall be left to be removed by hand excavation in
    order to obtain a firm thrust face against undisturbed ground. This trimming margin shall only
    be removed after laying and jointing of the pipes and the concrete for the thrust block shall be
    placed on the same day as the removal of the trimming margin.

    3 No pressure shall be applied to thrust blocks until the concrete has matured for at least

    .
    seven days.

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    4 "Rocker" pipes shall be installed adjacent to all concrete thrust blocks.

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    4.5.6 Property Connections Survey

    1
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    The Contractor shall complete and submit to the Engineer for approval a standard record
    sheet of every property connection. The information shall be recorded on forms provided by
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    the Engineer.

    2 The Contractor shall survey and prepare individual plans for each property at a scale of 1:500
    as

    (or such other scale as may be agreed by the Engineers Representative). These shall show
    existing plot boundaries, location of all buildings, location of all visible services and location
    se

    and level of all drainage services, including septic tanks. The plans shall indicate the nature
    of each building, clearly identifying kitchen, mess areas, toilets, washrooms and the drains
    serving these areas and gullies elsewhere. The plans shall identify the drains serving. The
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    plan shall be submitted on paper and AutoCAD compatible .dwg file. As a separate layer on
    the dwg file the Contractor shall mark his proposals for the property connection, including a
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    cross-section and this shall be submitted to the Engineers Representative for approval. No
    property connection work shall commence before approval to the proposed layout has been
    received in writing from the Engineers Representative.
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    3 In special cases only, an inspection chamber may serve more than one service connection.
    et

    Locations of inspection chambers and the layout of service connections shall be as approved
    by the Engineer.
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    4 Service connections shall be laid at sufficient depths to allow for adequate gradient being
    continued throughout the properly drainage system without the pipelines becoming too
    shallow for adequate cover to be provided over the pipe.

    4.5.7 Future House Connections

    1 During the course of the Contract the Engineers Representative and the Contractor shall
    agree on a programme regarding the positions and other details of the junctions to be left for
    future house connections. Such branches and junctions shall in all cases terminate in an
    approved stopper obtained from the pipe manufacturer.
    QCS 2014 Section 08: Drainage Works Page 30
    Part 04: Pipeline Installation

    2 The Contractor shall survey and prepare individual plans for each plot at a scale of 1:500 (or
    such other scale as may be agreed by the Engineers Representative). These shall show
    existing boundary walls or fences and ground level at each corner of the plot. The plan shall
    be submitted on paper and AutoCAD compatible dwg file. As a separate layer on the dwg file
    the Contractor shall mark his proposals for the property connection and this shall be
    submitted to the Engineers Representative for approval. No property connection work shall
    commence before approval to the proposed layout has been received in writing from the
    Engineers Representative.

    3 The Contractor shall produce accurate records of the exact location of all service connections
    and shall include for these in his rates.

    4.6 TESTING OF PIPELINES

    4.6.1 General

    .
    1 The Contractor shall submit for the Engineer's approval details of his proposed methods and

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    programme for testing (including details of test equipment) and shall arrange for all test to be
    witnessed by the Engineer or other person appointed by the Engineer. Test equipment shall

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    be approved by the Engineer and calibration certificates when requested by the Engineer
    shall be submitted. The Contractor shall provide all equipment necessary for carrying out
    testing and cleaning including pumps, gauges, piped connections, stop ends, and all other

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    temporary works. All water required for testing and cleaning the pipelines shall be from a
    source approved by the Engineer.
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    2 Pipelines shall be adequately restrained before being put under test except as hereinafter
    detailed. No testing will be permitted until seven days after thrust blocks and other holding
    as

    down works have been completed. Trenches may not be left open at joints before testing
    pipelines except as permitted by the Engineer who may lay down certain restricting
    se

    conditions. In addition to any tests of individual joints or other interim tests which may be
    designated elsewhere, the Contractor shall submit all parts of the pipelines to a final test.
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    3 This and the following Clauses on testing pipelines do not apply to GRP pipes for which
    ov

    testing requirements are given in the Project Specification where appropriate.

    4 Pipelines shall be tested in lengths between manholes or valve pits with lengths not
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    exceeding 400 metres except by agreement with the Engineers Representative. Testing
    shall not be against closed valves, and pipes of different diameters shall not be tested
    it

    together in the same test. The arrangements for testing a pipeline shall include provision for
    et

    purging the air from the pipeline during the test.


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    5 In all pipelines which are constructed with mechanical joints or with joints which permit axial
    movement, the joints shall be left open so that they may be inspected during hydraulic
    testing. In such cases only the barrels of the pipes shall be backfilled prior to hydraulic testing
    taking great care to avoid the joints and leaving sufficient space all round the joints to permit
    inspection and to undertake remedial measures should the joint be found to leak under
    hydraulic testing. After the successful completion of hydraulic testing, the joints shall, if
    specified, be wrapped, coated or sleeved as appropriate, and then backfilled in the manner
    specified elsewhere in this specification.

    6 The final test shall be applied in the presence of the Engineers Representative.

    7 The Contractor shall keep a record of all tests in a book which shall be available for
    inspection and handed over to the Engineers Representative on demand. The Contractor
    shall complete standard test record sheets as provided by the Engineer.
    QCS 2014 Section 08: Drainage Works Page 31
    Part 04: Pipeline Installation

    8 The section under test shall be properly sealed off with blank flanges or special stop end
    caps held securely in position by adequate temporary anchorages, and filled with water. All
    peak points of the pipeline shall be adequately vented during the filling operation using
    temporary bleed valves. All air valves shall be removed and all other valves shall be set in the
    open position.

    9 Pipe joints, valves and fittings shall be checked carefully for loose bolts or connections which
    might cause leakage and delay the execution of the tests.

    10 Should any section fail to pass the tests, the Contractor shall determine the cause of the
    failure and shall locate, excavate and repair any damage or leakage sustained by the pipeline
    before or during the tests and retest the section. The cost of such repair work, additional
    backfilling and reinstatement and abortive tests shall be borne by the Contractor.

    11 Water for the test shall be disposed of in a manner to be approved by the Engineer.
    Pumping water onto the site shall not be permitted.

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    12 The Contractor shall be responsible for ensuring that all test methods and procedures comply
    with his Health and Safety Plan.

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    13 The Contractor shall provide detailed method statements for his methods of testing access
    shafts, manholes and pipelines.

    4.6.2 Gravity Sewer Pipelines ta


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    1 Each pipeline 600 mm or less in diameter shall be tested by air test. Should any pipe fail the
    air test, the Engineer may order a water test to be carried out. Acceptance of the pipeline will
    as

    then be based on the results of the water test. All pipelines up to and including 1200 mm
    shall be tested by air test in accordance with the requirements of BS EN 752.
    se

    2 The Contractor shall, at his own expense, furnish all equipment and materials for making the
    tests. Each pipeline shall be tested before backfilling and also after backfilling before carrying
    er

    out road reinstatement or laying new road surfacing. Where the pipeline is located under a
    new road alignment, the pipeline will be tested after sub-base compaction in complete. All
    ov

    pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be
    clean and empty at the time of testing. Tests shall be performed in the presence of the
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    Engineer.
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    (a) Air Test:


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


    (ii) air shall be pumped in slowly to the pipe until a pressure of 100 mm water gauge
    is indicated on a manometer connected to the system. After the internal
    pressure of 100 mm water gauge is obtained, 5 min shall be allowed for the air
    temperature to stabilise within the pipe.
    (iii) Air may be added to restore the pressure to 100 mm water gauge. During a
    further period of 5 min, the pressure shall not fall below 75 mm water gauge
    without further pumping.
    (b) Water Test
    (i) all the joints of the pipeline shall be able to withstand a pressure of a minimum
    5m head of water, above the crown of pipe at the highest point of pipeline
    without leakage. A layer of embedding soil equal to the diameter of pipe shall
    be laid over the pipe to prevent the lifting of pipe while applying test pressure.
    However, all the joints shall be left open for the purpose of inspection for
    leakage if any. All branches and open ends shall be closed with stoppers,
    secured with longitudinal braces/thrust block, before testing begins
    QCS 2014 Section 08: Drainage Works Page 32
    Part 04: Pipeline Installation

    (ii) water shall be filled from the lowest point and air allowed to escape through an
    air vent fixed for the purpose at the high points of the pipeline section under test.
    The diameter of air vent shall be about one and half times the diameter of water
    inlet pipe to allow easy escape of air. No entrapped air shall remain in the
    pipeline while testing
    (iii) a pressure of 5 m head of water shall be maintained for one hour to allow initial
    absorption of water. After that the test pressure shall be maintained for 15 min
    and water added shall be measured. If water consumption in 15 min does not
    exceed 0.1 l/m2 of wetted inner pipe surface and if there are no visible leakage
    through joints, the pipeline shall be treated as passed.
    (c) Infiltration Test
    (i) the upper ends of the sewer and service connections shall be closed sufficiently
    to prevent the entry of water and pumping of groundwater shall be discontinued
    until the groundwater surface reaches its natural level before beginning the

    .
    infiltration test the dewatering system shall be stopped, but not be removed until

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    the infiltration test has been successfully completed or as otherwise permitted by
    the Engineer the infiltration shall not exceed 6 litres per millimetre diameter per

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    kilometre per day of the portion of sewer being tested, including the length of
    service connection entering that section.
    (ii)
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    the total length tested in one section shall not exceed 400 m in length. This
    length is dependent upon the type of deflection measuring equipment proposed
    qa
    by the Contractor if flexible pipes are used.
    (iii) no gravity pipeline will be accepted if the total infiltration exceeds the above
    as

    mentioned limit and joints will not be accepted if during an internal inspection,
    any infiltration is visible.
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    3 Prior to issue of a Certificate of Completion a CCTV survey shall, on the instruction of the
    Engineers Representative, be carried out on a representative sample of no more than 12%
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    of the length of constructed pipelines. Should this survey indicate sections of pipeline which
    fail to meet the specification requirements, the Contractor will be required to carry out
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    remedial works and undertake additional CCTV surveys at his expense.

    4.6.3 Pressure Pipelines


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    1 The pipeline shall be tested between valve chambers or into sections not exceeding 400 m in
    et

    length unless approved otherwise by the Engineer. The section tests shall be carried out as
    follows:
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    (a) each pipeline or section thereof shall be filled with water and all air removed as far as
    possible
    (b) the pressure shall then be raised by pumping in water until the test pressure is
    reached and shall be maintained at this level by further pumping until it is steady
    (c) pumping shall then be stopped and the time taken for the observed pressure to fall by
    1.0 m shall be recorded

    (d) pumping shall then be resumed and the quantity of water pumped in order to restore
    the test pressure shall be recorded
    (e) if after three hours the test pressure has not fallen by 1.0 m, pumping shall be
    resumed at that stage, the time being recorded as three hours
    (f) the rates of loss shall then be calculated as the recorded quantity divided by the
    recorded time
    (g) the test pump and gauge shall be connected to the pipeline at a location other than
    the highest point in the pipeline to facilitate release of air from the highest point
    QCS 2014 Section 08: Drainage Works Page 33
    Part 04: Pipeline Installation

    (h) the test pressure shall be such that the entire pipeline or section being tested is
    subjected to 1.5 times the working pressure, 1.25 times the maximum surge pressure
    or 800 kPa, whichever is the greatest
    (i) the loss shall not exceed 0.02 litres per mm diameter per kilometre per 24 hours for
    each 0.1 MPa of head applied
    (j) if the pipeline fails to pass the test, the faults shall be located and repaired and the
    pipeline retested until it passes the pressure test. All exposed pipe, fittings, valves
    and joints shall be visually inspected during the tests.

    2 When all sections have been joined together after completion of section testing, unless
    otherwise directed by the Engineer, the entire pipeline shall than be subjected to final test as
    follows:

    (a) all joints between individual test sections shall be left uncovered during this final test
    (b) the final test shall be carried out using the same procedure as the section test

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    (c) in all cases of water tests, where the measured leakage rate exceeds the allowable,

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    the Contractor shall, at his own expense, make all necessary repairs and carryout

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    additional testing until a satisfactory result is obtained
    (d) before pressure testing is started the Contractor shall recheck pipes and valves for
    cleanliness and shall recheck the operation of all valves. The "open" ends of the

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    pipeline or sections thereof) shall normally be stopped off by blank flanges or cap
    ends additionally secured where necessary by temporary struts and wedges. All
    qa
    anchor and thrust blocks shall have been completed and all pipe straps and other
    devices intended to prevent the movement of pipes shall have been securely
    fastened
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    (e) since valves cannot be guaranteed to be perfectly drop-tight, testing against closed
    valves which are connected to an existing system shall be prohibited; testing against
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    other closed valves (including air valves) not so connected, may be attempted if
    desired, provided the valves are suitably anchored against thrust. No claims
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    whatsoever will be entertained on account of leaking valves, or any other difficulties


    in closing off lengths of pipework for testing, which shall be entirely an obligation of
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    the Contractor
    (f) on successful completion of the final test, the exposed joints shall be covered and the
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    trench backfilled as specified in the appropriate Clause 2.3 of this Section.


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    3 The pipeline shall be tested for a period of at least 24 hours after which the test pressure
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    shall be restored by pumping and the quantity of water lost during the test measured.
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    4 Plastic irrigation drip pipe work shall be completely filled with water and visually inspected for
    leakage. No section showing signs of leakage will be accepted. In addition, any length of pipe
    which in the opinion of the Engineer or his designated representative is showing signs of
    degradation through contact with sunlight shall be cut out and replaced.

    4.6.4 Other Pressure Pipelines

    1 Water Pipelines and Other Pressure Piping Carrying Liquids

    (a) water pipelines and other pressure piping carrying surface water ground water and
    treated sewage effluent excluding raw sewage pressure pipelines having socket and
    spigot gasket joints shall be given a pressure and leakage test. Ductile iron or
    PVC-U pipe shall be tested to AWWA C066 ; steel pipe to AWWA C066

    (b) PVC-U treated sewage effluent pipework shall completely filled with water and
    visually inspected for leakage. No section showing signs of leakage shall be
    accepted.
    QCS 2014 Section 08: Drainage Works Page 34
    Part 04: Pipeline Installation

    2 Pressure Pipe, Flanged or Welded Joints

    (a) PVC-U, steel, cast iron, ductile iron or other pipe material, with solvent welded,
    welded, threaded, flanged, grooved end or flexible couplings and joints shall be
    pressure tested. No leakage shall be permitted.

    3 Pressure Air and Gas Piping:

    (a) All piping carrying air or other gasses under pressure shall be given a pressure test.
    No leakage is permitted. Low pressure air piping shall be tested pneumatically. Air
    pressure of 140 kPa shall be applied to piping and fittings. High pressure air piping
    shall be tested to 1400 kPa. There shall be no drop in pressure in a 24-hour period

    (b) Leaks shall be located and repaired to the satisfaction of the Engineer. Pressure
    drops due to thermal contraction are acceptable if the pressure returns to the original
    test pressure after 24 hours.

    .
    4 All piping, including valves, shall be field tested at the specified pressure with duration of two

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    hours minimum, for each pressure test. Piping conveying liquids between process tankage,
    not subject to pumping, shall be tested to the maximum possible pressure that can be

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    obtained under static conditions. Air piping shall be tested using air or nitrogen.

    5 All exposed pipe, fittings, valves, hydrants, and joints shall be carefully inspected before

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    either being cast in concrete or during the open trench tests, or both. All defects discovered
    shall be corrected by removal and replacement, as approved by the Engineer, and the work
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    then retested to demonstrate satisfactory performance.

    6 Where practical, no concrete encasement or backfilling of pipe joints will be permitted before
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    the satisfactory completion of the tests in any given section.


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    4.6.5 MDPE and HDPE Pressure Pipelines


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    1 Upon substantial completion of the pipeline or major sections, the line shall be cleaned and
    hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior
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    to commissioning. Testing shall be performed in accordance with the Finnish Standard SFS
    3115:E and the procedure described below. The Contractor shall supply all necessary fittings,
    equipment and facilities required to undertake the testing.
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    2 The Contractor shall prepare a detailed Method Statement for the pressure test that shall
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    follow the outline test procedure described below and be subject to the approval of the
    Engineer.
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    (a) Seal the pipeline. Fix all blank flanges. Remove air valves. Remove all on line
    equipment that may be damaged by high pressure.
    (b) Only test against blank flanges, do not attempt to test against closed valves.
    (c) Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints
    exposed where practical.
    (d) If backfilling is not practicable schedule the tests for early morning or evening.
    (e) Fill the pipeline from the lowest point. Bleed the air from all high points and flange
    points where it is possible and tighten once water begins to spill.
    (f) When the line is full, close off the filling valve and check all flanges and the small
    diameter test pipework for leaks.
    (g) Phase1
    Commence raising the pressure at the filling point to the operating pressure or a
    pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and
    add water whenever the pressure drops by 0.2 bar in order to maintain a steady
    pressure.
    QCS 2014 Section 08: Drainage Works Page 35
    Part 04: Pipeline Installation

    (h) Visually inspect the pipe length for leakage.


    (i) Phase2
    After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar,
    whichever is higher, as quickly as is practical. Again maintain this pressure for two
    hours by adding water whenever the pressure drops by 0.2 bar.
    (j) Visually inspect the pipe length for leakage.
    (k) Phase3
    At the end of the second two hours release the pressure back down to the phase I
    level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes
    and as quickly as is practical, in a controlled manner.
    (l) Phase3Case1
    If after one hour the pressure in the pipelines remains at or above the operational
    pressure, the test is considered to be completed with the pipeline passing the
    hydrostatic test.

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    (m) Phase3Case2

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    If after one hour the pressure in the pipeline has fallen below the operational pressure,
    water shall be added to raise the pressure back to the operating pressure level, having

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    first noted the low pressure before adding any water.
    (n) Phase3Case2

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    Measure the added water by draining it off into a measuring cylinder. (i.e. reduce
    pressure to the previously recorded low value and save the water bled off). The
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    measured quantity is then compared against the allowable quantity to determine if the
    pipeline passes the hydrostatic pressure test.
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    QCS 2014 Section 08: Drainage Works Page 36
    Part 04: Pipeline Installation

    Figure 1 Graphical Representation of the Hydrostatic Test Process


    Case 1 Pipeline passes test without adding any make up water

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    Figure 2 Graphical Representation of the Hydrostatic Test Process


    Case 2 Water to be added to determine if the pipeline passes or fails
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    QCS 2014 Section 08: Drainage Works Page 37
    Part 04: Pipeline Installation

    3 If during Phase 3 the pressure within the pipeline remains at or above the operational
    pressure of the pipeline for a period of at least one hour, the pipeline is considered to have
    passed the hydrostatic test.

    4 If water needs to be added the pipeline is considered to have passed the hydrostatic test if
    the quantity of water added in terms of litres of water per km of pipeline length per hour of the
    phase 3 period is less than that given in the following expression and in Figure 3.

    Q Di/50 1 (litres / km/ hour)

    Q = added water in litres.

    Di = internal diameter for the pipeline in mm.

    Figure 3. Hydrostatic Test Allowable Quantities of Make Up Water

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    Hydrostatic Test
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    Pass
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    5 The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be
    connected to the feed pipework.
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    6 The small diameter test pipework shall include a bleed valve at upper end of the pipeline and
    at all high points together with feed pipework and valve at the lower end of the pipeline. The
    feed pipework shall include a means of draining off the water in to a measuring cylinder that
    shall have a capacity of at least 2 litres capacity, graduated to 100 mls.

    7 The Contractor shall also have a thermometer for air and water temperature measurement.

    8 Care should be taken not to over pressure the lower end of the system during testing.
    Gauges should always be placed at the lower end of the length under test. As far as possible
    the difference between the lower and upper end should be kept to one bar. It is recognized
    that this may not always be possible when longer lengths are being tested, or where the
    slope of the pipeline makes it impractical.

    9 Where the phase II pressure is within the pressure rating of the pipe and test temperatures
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    are 30 C or less no adjustment of test pressure is necessary.
    QCS 2014 Section 08: Drainage Works Page 38
    Part 04: Pipeline Installation

    10 When ambient temperatures at the time of test are over 30C and test pressures are over the
    pressure rating of the pipe then it may be necessary to modify the test pressure according to
    the table below or as agreed with the pipe manufacturer.
    Test Temp.
    O 32 38 43 49 54 60
    ( C)

    Multiplier 0.9 0.8 0.75 0.65 0.6 0.5

    11 When undertaking the testing the Contractor shall also take in to account the following points.

    (a) Care should be taken that any mechanical elements on the system are protected from
    elevated pressure or completely removed from the pipeline.
    (b) Do not subject the line to prolonged over-pressure. Always aim to complete the
    procedure within one working day.
    (c) During the summer make sure that the pipe is not subject to direct sunlight during

    .
    testing.

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    (d) During pressure testing pay full attention to the HSE aspects of the procedure. In

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    particular keep the general public away from high pressure test areas.
    (e) The test equipment must be capable of pressurizing the test length within a reasonable
    time. If the procedure becomes protracted (beyond one working day) the test length

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    may be modified or reviewed. Extremely long test lengths may be subject to special
    procedures.
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    4.7 MISCELLANEOUS ITEMS
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    4.7.1 Manhole Covers and Frames


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


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    (b) Documentation identified under Annex A to BS EN 124, concerning Independent Third


    Party Inspection.
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    (c) Independent random sample testing at an approved testing facility to demonstrate full
    compliance with all aspects of the code i.e. load testing and dimensional tolerances.
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    (d) Production facilities shall be quality assessed in accordance with ISO 9000 or EN
    29002 (BS 5750).
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    2 Where manholes are located in road carriageway, the covers shall be non-rock double
    triangular Class D400 unless otherwise designated. The double triangular cover shall be
    loosely coupled with stainless steel bolts. The frames for sewer and surface / ground water
    manholes shall provide a minimum access opening of 750mm square. The frames for TSE
    chambers shall provide a minimum access opening of 675mm square.

    3 Manhole covers in paved areas, car parks, verges, roads within property boundaries, and
    other areas accessible to pedestrians and light vehicles, shall be non-rock double triangular
    Class B125 unless otherwise designated. The double triangular covers shall be loosely
    coupled with stainless steel bolts plate. The frames for sewer and surface / ground water
    manholes shall provide a minimum access opening of 750mm square. The frames for TSE
    chambers shall provide a minimum access opening of 675mm square.

    4 All castings shall be grit blasted and coated on all exposed faces with a zinc primer and coal-
    tar epoxy paint finish in accordance with Part 8 of this Section which shall result in a smooth
    coating, tough and tenacious when cold, and neither tacky nor brittle.
    QCS 2014 Section 08: Drainage Works Page 39
    Part 04: Pipeline Installation

    5 The covers and frames on foul sewers shall incorporate a removable self-sealing GRP or
    similar corrosion resistant plate meeting the requirements of Part 7 of this Section. The plate
    shall fit between the cover and the frame such that no surface area of the frame shall be
    exposed to the atmosphere within the manhole. This shall be achieved by the inclusion of a
    neoprene sealing ring or by a similar approved method. The plate shall be complete with a
    lifting handle on the upper surface. The design of the frame and cover and plate shall be
    subject to the approval of the Engineer. A heavy grease seal is to be formed in all cases
    between the cover and frame to prevent the ingress of sand.

    6 Manhole covers for sewerage, surface water and treated sewage effluent systems shall have
    the following words embossed in both English and Arabic, respectively:

    (a) Sewerage: Drainage


    Foul Sewer
    (b) Surface water: Drainage

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    Surface Water

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    (c) Treated sewage effluent: Drainage

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    Treated Sewage Effluent.

    7 The size of lettering shall be approved by the Engineer.

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    The Contractor shall supply one pair of manhole keys or prying and lifting bar, as appropriate
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    with each 30 covers provided with a minimum of one tool for each type cover. Keys and
    prying and lifting bars shall be of approved appropriate design to match the different cover
    configurations. Keyways in manhole covers shall be of the closed type.
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    9 Any manhole covers and frames on sewer or surface / ground water manholes that are
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    damaged or otherwise disturbed during the execution of the Works shall be replaced with
    covers and frames with a minimum clear opening of 750mm square and incorporate a GRP
    sealing plate. If the opening through the concrete cover slab is less than 750mm square, then
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    the concrete slab shall also be replaced.


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    10 Manhole covers for foul sewerage, surface water and treated sewerage effluent shall be
    provided with inscriptions both in Arabic and English cast into the top surface of the cover.
    The lettering shall conform to the details given elsewhere in these documents or to the
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    current details available from Drainage Affairs.


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    4.1.2 Duct Covers and Frames


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    11 Duct covers and frames shall be of cast iron, galvanised mild steel or aluminium as shown on
    the Drawings, and shall be waterproof, non-rocking and recessed for filling with concrete.

    12 Cast iron duct covers and frames shall be obtained from an approved experienced
    manufacturer, shall have machined seating faces and sloping mating faces to facilitate sliding
    out of covers. The covers shall be capable of withstanding a 5 tonne wheel load when the
    recesses are filled with Grade SRC 25 concrete, or such other load as may be shown
    elsewhere in the Contract Document.

    13 Galvanised steel covers and frames shall be obtained from an approved experienced
    manufacturer. Covers shall have solid bases fitted with reinforcing rods and where detailed
    on the drawings shall incorporate locking bolts. Covers shall be capable of withstanding a 5
    tonne wheel load when filled with Grade SCR 25 concrete, or such other load as may be
    shown elsewhere in the Contract Document. Covers shall generally be filled with concrete,
    but finished with tiling to match the surrounding floor finish.
    QCS 2014 Section 08: Drainage Works Page 40
    Part 04: Pipeline Installation

    14 Aluminium duct covers and frames shall be fabricated from aluminium alloy Grade 6063-T6
    or other such chemically resistant alloy which the manufacturer can demonstrate will
    withstand aggressive atmospheres likely to be encountered. Covers shall have solid bases,
    and shall incorporate reinforcing bars held in place in plastic clips. Those faces of the frame
    which will come into contract with cement mortar or concrete shall be painted with two coats
    of bituminous paint before installation of the frame.

    15 All covers shall be installed strictly in accordance with the manufacturers instructions.

    16 Two complete sets of lifting keys including any necessary spanners shall be provided in each
    room in which ducts covers are installed.

    17 A heavy grease seal is to be formed between the cover and frame to prevent the ingress of
    sand.

    18 Multiple covers shall have removable intermediate beams.

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    4.7.2 Hinged Aluminium Access Covers

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    1 Hinged aluminium access covers shall be fabricated from chequer or ribbed plate. The
    2
    covers shall be designed to carry a uniformly distributed load of 7.5 kN/m , and deflection
    under this loading shall not exceed one percent of the span.

    2 ta
    The frame shall be made from aluminium alloy complying with BS 1474 Grades 6063-T6 or
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    6082-T6.

    3 Where a cover is to be located within tiled areas, the frame shall be made from channel
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    sections. The outer vertical arm of the channel frame shall be set flush with the top of the
    adjacent floor finishes. The inner vertical arm shall be shorter to allow the chequer plate to sit
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    the inner arm, while allowing the chequer plate cover to be flush with adjacent floor finishes.
    The edges of the chequer plate cover shall be turned down into the channel section. Hinges
    shall not stand proud of the cover and sealed lifting eyes shall be provided complete with two
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    lifting keys for each cover.


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    4 Where a cover is to be located on concrete upstands or flat concrete surfaces, the frame
    shall be made from angle sections. The edges of the chequer plate cover shall be turned
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    down over the angle frame to provide a weatherproof cover. A lifting handle shall be provided
    on the edge opposite the hinges and a hasp provided for locking the cover with a padlock.
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    The frame shall be bolted down to the concrete below using a minimum of four 10 mm
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    diameter stainless steel acrylic resin anchors.


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    5 Fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy from
    other material.

    4.8 FUTURE SEWER CONNECTION

    4.8.1 General

    1 All stub pipes and pipes built into manholes for future connections are to be sealed with an
    approved stopper, obtained from the same manufacturer as the pipe.

    2 Marker posts shall be provided at the ends of all pipes left for future connection except where
    a single stub pipe is built into a manhole and are to be located as directed by the Engineers
    Representative.
    QCS 2014 Section 08: Drainage Works Page 41
    Part 04: Pipeline Installation

    4.9 INSITU LINING OF EXISTING MANHOLES

    4.9.1 General

    1 Where directed by the Engineer, the Contractor shall apply a GRP lining to all internal
    surfaces of an existing manhole. The lining shall generally comply with the requirements of
    Specification Clause 4.4.1.

    2 The cover slab and manhole cover shall be removed. The slab shall be disposed to an
    approved tip. The manhole cover and frame shall be thoroughly cleaned, treated with two
    coats of bituminous paint and submitted to Drainage Affairs Store.

    3 All surfaces to be lined shall be clean and dry, step irons and any unsound materials shall be
    removed to the satisfaction of the Engineer prior to the commencement of any lining or
    sealing work.

    .
    4 For walls a preformed liner sized to fit in the existing manhole may be used. The joint

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    between the base of the liners and existing benching shall be sealed into a chase cut into the
    existing benching by a heavy duty epoxy resin based sealant approved by the Engineer,

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    which must be applied strictly in accordance with the manufacturer's instructions. The space
    between the existing internal concrete wall of the manhole and the liner shall be filled using
    an approved non-shrink cementitious grout.

    5 ta
    Alternatively an in situ wall lining may be used. The walls shall first be made good with 3:1
    qa
    sand cement mortar and the surfaces to be lined shall be lightly abraded. An in-situ lining
    6mm deep in compliance with Specification Clause 4.4.1.9 shall then be formed.
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    6 On completion of the lining a new GRP ladder shall be installed in accordance with
    Specification Clause 4.4.1.15, if shown on the Contract Drawings.
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    7 A new cover slab and manhole cover shall be provided. The cover slab shall comply with
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    Specification Clause 4.4.1.9. The manhole cover and frame shall comply with Specification
    Clause 4.6.1.
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    8 The Contractor shall provide the Employer with a 7-year unconditional guarantee against
    failure of all GRP linings whether caused by defective materials or workmanship. The
    o

    guarantee shall be valid from the date of completion of the installation and must be handed to
    it

    the Engineer before the issue of the Certificate of Completion.


    et

    END OF PART
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    QCS 2014 Section 08: Drainage Works Page 1
    Part 05: Valves, Penstocks and Appurtenances

    5 VALVES, PENSTOCKS AND APPURTENANCES ....................................... 3

    5.1 GENERAL ...................................................................................................... 3


    5.1.1 Scope 3
    5.1.2 References 3
    5.1.3 Submittals 4
    5.1.4 Quality Assurance 6
    5.1.5 Delivery, Storage and Handling 6
    5.2 MATERIALS .................................................................................................. 6

    5.3 SLUICE VALVES ........................................................................................... 7

    5.4 BUTTERFLY VALVES ................................................................................... 8

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    5.5 REFLUX VALVES .......................................................................................... 9

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    5.6 PLUG VALVES ............................................................................................ 10

    5.7
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    SURFACE BOXES ...................................................................................... 10
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    5.8 VALVE OPERATING TEE KEYS................................................................. 11
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    5.9 AIR VALVES ................................................................................................ 11


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


    5.10.1 General 12
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    5.10.2 Pressure Reducing Valves 12


    5.10.3 Pressure Relief Valves 12
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    5.10.4 Pressure Regulating and Sustaining Valves 12


    5.11 PENSTOCKS ............................................................................................... 12
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    5.11.1 General 12
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    5.11.2 Cast Iron Penstocks 12


    5.11.3 Stainless Steel Penstock 14
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    5.11.4 Plastic Penstocks 14


    5.11.5 Stoplogs 15
    5.12 OPERATING DEVICES ............................................................................... 15
    5.12.1 Lifts 15
    5.12.2 Liftnut 16
    5.12.3 Gear Lift 16
    5.12.4 Handwheel 16
    5.12.5 Stem Covers 16
    5.12.6 Actuators 16
    5.13 FLAP VALVES ............................................................................................. 17
    5.13.1 Flap Valves (General Purpose) 17
    5.13.2 Flap Valves for Sea Water Applications 17
    QCS 2014 Section 08: Drainage Works Page 2
    Part 05: Valves, Penstocks and Appurtenances

    5.14 MISCELLANEOUS VALVES AND APPURTENANCES .............................. 17


    5.14.1 Ball Float Valves 17
    5.14.2 Globe Valves 18
    5.14.3 Quick Coupling Valves 18
    5.14.4 Emitters 18
    5.15 FITTINGS .................................................................................................... 18
    5.15.2 Flanges, Gaskets, and Bolts 18
    5.16 MECHANICAL COUPLINGS ....................................................................... 18
    5.16.1 Grooved End Couplings 19
    5.16.2 Flexible Couplings 19
    5.17 FLOW CONTROL ........................................................................................ 19

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    5.17.1 Vortex Flow Control Devices 19

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    5.18 INSTALLATION AND TESTING .................................................................. 20

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    5.18.1 Installation 20
    5.18.2 Testing 20
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    QCS 2014 Section 08: Drainage Works Page 3
    Part 05: Valves, Penstocks and Appurtenances

    5 VALVES, PENSTOCKS AND APPURTENANCES


    5.1 GENERAL

    5.1.1 Scope

    1 This part includes the specification for the manufacture, testing and supply and installation of
    valves, penstocks and appurtenances complete with frames, supports, anchor bolts, stems,
    stem guides and other appurtenances.

    2 Related Sections and Parts are as follows:


    This Section
    Part 1, General

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    Part 3, Pipes and Fittings Materials
    Part 4, Pipe Installation

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    Part 6, Miscellaneous Metal Works
    Part 8, Protective Coatings and Painting

    Section 1, General
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    Section 9, Mechanical and Electrical Equipment
    Section 10, Instrumentation Control and Automation.
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    3 All valves are to be fixed to the pipelines with adaptor flanges for easy removal or installation.
    se

    5.1.2 References
    er

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


    ANSI B18.2.1..............Square and Hex Bolts and Screws
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    ANSI B18.2.2..............Square and Hex Nuts


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    ASTM B62 ..................Composition Bronze or Ounce Metal Castings


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    ASTM D256 ................Test Methods for Impact Resistance of Plastics and Electrical
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    Insulating
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    Materials
    ASTM D570 ................Test Method for Water Absorption of Plastics
    ASTM D638 ................Test for Tensile Properties of Plastics
    ASTM D648 ................Test Method for Deflection Temperature of Plastics Under Flexural
    Load
    ASTM D695 ................Test Method for Compressive Properties of Rigid Plastics
    ASTM D696 ................Test Method for Coefficient Linear Thermal Expansion of Plastics
    ASTM D790 ................Standard Test Methods For Flexural Properties of Unreinforced and
    Reinforced Plastics and Electrical Insulating Materials
    ASTM D1784 ..............Specification for Rigid Polyvinylchloride) (PVC) Compounds and
    Chlorinated Polyvinylchloride (CPVC) Compounds
    ASTM D2000 ..............Classification System for Rubber Products in Automotive Applications

    AWWA C500 ..............Metal-Seated Gate Valves


    QCS 2014 Section 08: Drainage Works Page 4
    Part 05: Valves, Penstocks and Appurtenances

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


    AWWA C507 ..............Ball Valves 150 mm Through 1200 mm
    AWWA C510 ..............Double Check Valve Backflow-Prevention Assembly.

    BS 4772......................Ductile iron pipes and fittings


    BS 5163......................Predominantly key-operated cast iron gate valves for water works
    purposes
    BS 970 Part 1 .............General inspection and testing procedures and specific requirements
    for carbon, carbon manganese alloy and stainless steel
    BS 2872......................Copper and copper alloy forging stock and forgings
    BS 2874......................Copper and copper alloy rods and sections (other than forging stock)
    BS 3416......................Specification for bitumen based coatings for cold application

    .
    BS 4164......................Specification for coal-tar-based hot-applied coating materials

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    BS EN 593..................Butterfly valves
    BS EN 598 ------- Face-to-face valve dimensions
    BS EN 1092................Flanges and their joints
    BS EN 1171................Cast iron gate valves ta
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    BS EN 1561................Flake graphite cast iron
    BS EN 1563................Founding. Spheroidal graphite cast iron
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    BS EN 1982................Copper alloy ingots and copper alloy and high conductivity copper
    castings
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    BS EN 3196................Nuts, hexagonal, self-locking in heat resisting steel


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    BS EN 12334..............Cast iron check valves for general purposes


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    ISO 9000 ....................Quality Systems


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    5.1.3 Submittals
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    et

    1 The Contractor shall obtain Engineers approval of submittals before placing order for the
    following items.
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    2 Valves. Complete data for the supply and installation of all valves and appurtenances shall
    be submitted as follows:

    (a) Product data:


    (i) for each type and model of valve, provide
    assembly instructions,
    preventative/corrective maintenance instructions
    (ii) for each actuator, provide
    currents at the specified voltage corresponding to locked rotor,
    maximum seating torque,
    average running load, and speed and full information concerning actuator
    dimensions and weights shall be provided
    (iii) identification of valves and accessories by tag numbers, where applicable.
    QCS 2014 Section 08: Drainage Works Page 5
    Part 05: Valves, Penstocks and Appurtenances

    (b) The following detailed written procedures shall be submitted to supplement the above
    data:
    (i) installation procedures for fixing, supporting, and anchoring valves
    (ii) test procedures for adjusting and testing valve assemblies.

    3 Penstocks:

    (a) Complete fabrication, assembly, foundation, and installation drawings, together with
    detailed specifications and information covering performance and materials of
    construction, power drive assembly, devices, and other accessories shall be
    submitted as follows:
    (i) Shop drawings, data and specifications for the equipment shall include, but not
    limited to:
    anchor bolt placement in the concrete structure including projections from

    .
    concrete or other surfaces

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    gate size, model numbers, opening sizes, elevations, locations, and

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    materials of construction

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    stem sizes including details of connections, thread directions, and stops, and
    calculations for stem diameter and operators
    stem guide details and locations

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    gear box types, model numbers, and ratios, including connections furnished
    for each type
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    wall thimbles
    motor data, including the motor manufacturer; minimum guaranteed
    efficiency and power factor at full load, 3/4 load, and 1/2 load; locked rotor
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    current in amps; full load current in amps; motor speed in rpm; and mounting
    details
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    (ii) Factory Test Reports:


    Before shipment of any material specified herein, the Contractor shall submit
    er

    the results of all test reports for the approval of the Engineer.
    ov

    4 Operations and Maintenance Manuals:

    (a) The Contractor shall submit five copies of complete operation and maintenance
    o

    manuals for penstocks and valves written in English in accordance with Part 1 of this
    it

    Section. Required operation and maintenance data shall include, but not limited to
    et

    (i) complete, detailed written operating instructions for each product or piece of
    m

    equipment. Manuals must be specific to the products supplied herein and the
    application and operating conditions in Qatar. General manuals will not be
    accepted
    (ii) complete, detailed preventative maintenance instructions
    (iii) a complete inventory of all parts and components
    (iv) recommended spare parts lists and sources of supply for the parts
    (v) all safety instructions relating to operation and maintenance procedures
    (vi) name, address and phone number of manufacturer, manufacturer's authorised
    service representative
    (vii) troubleshooting instructions.
    QCS 2014 Section 08: Drainage Works Page 6
    Part 05: Valves, Penstocks and Appurtenances

    5.1.4 Quality Assurance

    1 Valves, penstocks and appurtenances shall be supplied by approved manufacturers as


    designated in the Project Specification. Production facilities shall be quality assessed in
    accordance with ISO 9000 or equivalent.

    5.1.5 Delivery, Storage and Handling

    1 Packaged items shall be stored in their original packing and wrappers until ready for
    inspection by the Engineer. After inspection, all packaged items shall be repacked and
    rewrapped such that the items are sealed to the satisfaction of the Engineer, and stored until
    ready for use or installation.

    2 Valves and appurtenances shall be stored off the ground, protected from dirt and moisture,
    and protected from foreign material entering the ends.

    .
    3 All equipment shall be stored and handled in such a manner to protect equipment, finishes,

    l
    .l.
    and coatings, both internal and external.

    rw
    4 During storage, gates for penstocks shall be placed in a position to support and prevent
    warping of gates and stems.

    5.2 MATERIALS
    ta
    qa
    1 Cast iron shall conform to BS EN 1561 minimum Grade 250 unless otherwise specified.
    as

    2 Ductile iron shall conform to BS EN 1563 unless otherwise specified.

    3 Aluminium bronze shall conform to BS 2872 Grade CA 104


    se

    4 Bronze shall conform to ASTM B62 Grade 1, except that the maximum zinc allowance shall
    er

    be seven percent and the maximum aluminium allowance be two percent, unless otherwise
    specified.
    ov

    5 Gun metal shall conform to BS EN 1982 Grade LG2


    o

    6 Stainless steel shall conform to BS 970 Grade 316 S 31 unless otherwise specified.
    it
    et

    7 Duplex stainless steel shall conform to BS EN 1.4507 unless otherwise specified.


    m

    8 Manganese steel shall conform to BS 970 Pt 1 Grade ISO M19.

    9 Anchor bolts, assembly bolts, screws, nuts, and washers, including anchor bolts used in the
    installation and assembly of each unit shall be stainless steel unless otherwise specified, and
    of ample size and strength to safely withstand forces created by operation of the unit while
    subject to the hydrostatic heads described herein. The quantity and size of fasteners shall be
    as recommended by manufacturer, and as approved by Engineer. All bolt heads and nuts
    shall be hexagonal. Anchor bolts shall be furnished with two nuts each to facilitate
    installation and alignment.

    10 All hand wheels, headstocks, foot brackets, guide brackets and thrust tubes shall be cast
    iron. All other materials for valves, penstocks and appurtenances shall be as specified for
    each item.

    11 Unless otherwise stated Cast iron valves, penstocks and appurtenances shall be prepared
    and painted in accordance with part 8 of this Section.
    QCS 2014 Section 08: Drainage Works Page 7
    Part 05: Valves, Penstocks and Appurtenances

    5.3 SLUICE VALVES


    1 These specifications are applicable to all sizes of sluice valves larger than 80 mm diameter.
    Sluice valves shall be of the following types.

    (a) Potable and treated sewage effluent - 80mm diameter up to and including 300mm
    diameter, to BS 5163 with resilient seating.
    (b) All other uses other than (a) above, 80mm diameter up to and including 1,000mm
    diameter to BS EN 1171metal seated.

    2 Valves shall be of the double flanged cast iron wedge-gate type unless otherwise stated.
    Valves shall be cast iron body with renewable gun metal faces on body and wedge and bolt-
    on cast iron bonnet. All exposed valves shall be of the rising stem type unless otherwise
    specified or shown on the Contract Drawing. Rising stem valves shall also incorporate a
    combined yoke. Valves shall close clockwise.

    .
    3 Valves pressure ratings shall equal the class of pipe unless otherwise indicated on the

    l
    .l.
    Drawings.

    rw
    4 Valve stems shall be of stainless steel SS316 S31, machined all over, with a machine cut
    robust trapezoidal or square form thread, operating in gunmetal.

    5
    ta
    Stem seals on valves of 350mm diameter and above shall be of the stuffing box and gland
    form arranged for easy replacement of packing and seal and shall be accessible for
    qa
    maintenance without removal of the valve from service. Stem seals on valves below 350mm
    diameter may be stuffing box and gland or 'O' ring. If 'O' ring seals are provided they shall be
    arranged such that they can be replaced without removal of the valve from service. If 'O' ring
    as

    stem seals are provided, the Contractor shall provide with the valve, two replacement sets of
    rings labelled with the project number, manufacturer, valve model reference and size of
    se

    valve.
    er

    6 Valves shall be provided with suitable handwheels as follows:

    (a) diameter shall be adequate for the duty required


    ov

    (b) gearing shall be supplied where necessary to ensure that the required operating force
    applied by hand to the rim of the wheel does not exceed 250N (25Kgf)
    o

    (c) Handwheels shall have smooth rims and the direction of closing, which shall be
    it

    clockwise, shall be cast on them.


    et

    7 The following shall apply to spindles :


    m

    (a) where possible and providing the valve is not subject to submergence, spindles shall
    be of the non-rising type and a cast iron bridle piece, or similar, shall be incorporated
    on valves of the rising spindle type for this purpose.
    (b) for valves of 300mm bore and above, and for all motorised/actuated valves spindles
    shall be of the rising type. Thrust tubes shall be provided between the valve and
    headstock in order to absorb the thrust in both direction of operation. Thrust tubes
    shall incorporate all necessary fixings brackets and spindle guide plates. Headstocks
    shall incorporate a valve position indicator.
    (c) where rising stem valves are subject to submergence the extension spindle shall also
    be of the rising type with the threaded portion positioned above top water level.
    (d) extended spindle installations shall include all necessary brackets, intermediate
    supports etc.
    (e) where extended spindles require to be operated at open flooring level, spindle guides
    or guide brackets shall be provided close to flooring level.
    QCS 2014 Section 08: Drainage Works Page 8
    Part 05: Valves, Penstocks and Appurtenances

    (f) all spindles shall be of stainless steel Grade 316S31 and shall be compliant with the
    requirements for valve stems.

    8 Extension spindle couplings shall be of the muff type and shall be drilled with a nut and bolt
    for securing the spindle to the valve stem, which will likewise be drilled to accept the bolt.

    9 Vandal and weatherproof clear polycarbonate tube covers shall be securely fitted to protect
    the threads of rising stems and spindles. Tubes shall be clearly and permanently engraved
    to indicate the position of the valve.

    10 Where valves are required to be operated by tee keys, spindle caps shall be fitted. The caps
    shall be drilled and each provided with nut and bolt for securing to the spindle which shall
    likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied complete
    with operating tee key. The extended spindle shall be such that the tee key will be operated
    at 0.9 to 1.2 m above floor level.

    11 Where sluice valves above 350 mm bore are mounted with the spindle in the horizontal

    l .
    plane, valve bodies shall be fitted with renewable gunmetal machined gate slides and the

    .l.
    gates with renewable hard bronze shoes accurately machined to reduce sliding fraction.

    rw
    12 All sluice valves above 500 mm bore (300 mm if power actuated) shall be provided with
    jacking screws. Valves above 350 mm bore where mounted in a horizontal pipeline shall be
    provided with feet.
    ta
    qa
    5.4 BUTTERFLY VALVES
    1 Butterfly valves shall comply with BS EN 593 and be of the double flanged, non-wafer,
    as

    double eccentric (Offset) type. The valves shall be designed such that the body and disc seat
    rings can be easily replaced.
    se

    2 Valves shall be suitably designed to protect the disc edge from the effects of corrosion and
    erosion.
    er

    3 The valve body ends shall be double flanged and the flange dimensions shall comply with the
    ov

    relevant requirements of BS EN 1092. The body shall be manufactured from close grained
    cast iron lined with rubber unless otherwise specified. The body parts shall be circular and
    the diameter not less than that of the nominal pipe bore. The valve body shall be provided
    o

    with suitable lifting lugs.


    it
    et

    4 The disc shall be designed to withstand the maximum pressure differential across the valve
    in either direction of flow. The disc shall be contoured to ensure the lowest possible
    m

    resistance to flow and shall be suitable for throttling operation. Disc material shall be duplex
    stainless steel.

    5 The shaft shall be designed to withstand the maximum torque that will be imposed by the
    operator. It may be in one piece or attached as two stub ends on opposite sides of the disc.
    The stub end shall be of polygon profile type conforming to P3G or P4C. The means of
    attachment of the shaft to the disc shall be by using fixings in a homogeneous corrosion-
    resistant material of a pattern which precludes the assembly becoming loose in operational
    service. Grub screws, pins (parallel or taper) or clamps shall not be acceptable. The shaft
    material shall be stainless steel SS316 S31. Self-lubricating PTFE faced bearings with O
    ring seals shall be provided.

    6 The body seat shall be stainless steel SS316 S31 and the disc seat shall be one piece
    moulded nitrile rubber. They shall be designed to be drop tight in either direction at
    maximum differential pressure.

    7 Valves shall be provided with suitable stops to prevent movement of the shaft beyond the
    limits corresponding to fully open and fully closed position of the disc.
    QCS 2014 Section 08: Drainage Works Page 9
    Part 05: Valves, Penstocks and Appurtenances

    8 A suitable external locking device shall be provided on the non-drive shaft end, to enable the
    geared unit to be removed with the valve remaining in service in the open or closed position.

    9 Fasteners like nuts, bolts and washers of stainless steel shall be provided.

    10 Unless otherwise specified each valve shall be provided with a suitable handwheel of
    adequate diameter for the duty required and gearing shall be supplied where necessary to
    ensure that the required operating force applied by hand to the rim of the wheel does not
    exceed 25 kgf.

    11 Extension spindles, headstocks and foot brackets shall be provided where specified.
    Headstocks shall incorporate a valve position indicator.

    12 The valve shall be closed by clockwise movement of an actuator or handwheel. Direction


    arrows clearly indicating 'open' and 'closed' positions shall be provided on the actuator or cast
    on the handwheel.

    l .
    .l.
    13 Valves shall be provided with a position indicator to show the positions of the disc, mounted
    on the driven shaft end.

    rw
    14 All Valves above 350 mm diameter shall be provided with lifting lugs or eye-bolts

    5.5 REFLUX VALVES


    ta
    qa
    1 Unless otherwise specified Reflux valves shall be swing type, double flanged cast iron
    conforming to BS EN 12334. Flange dimensions shall comply with the relevant requirements
    on BS EN 1092 PN16. Reflux valve shall have face-to-face dimensions in accordance with
    as

    BS EN 558.
    se

    2 The valves shall be of the quick acting single door type designed to minimise slam on closure
    by means of heavy gunmetal-faced doors weighted as necessary. The valves shall be fitted
    er

    with renewable gunmetal door sealing faces which shall be positively fixed. The door hinge
    pin/shaft shall extend through a sealing gland on the side of the body and be fitted with an
    ov

    external lever to permit back flushing.

    3 Glands shall be of the stuffing-box type with the exception that for valves below 450 mm bore
    o

    they shall be of the O ring type.


    it

    4 The valve door shall be weighted to suit the application and the lever shall be of the heavy
    et

    duty type designed for the additional of external weights should these be required at some
    m

    future date.

    5 Where there is a likelihood of surge pressures being generated reflux valves shall be of the
    low loss non-slam wafer type. They shall feature a spring action giving drip tight shut-off.
    The movement of the sealing plate shall not lead to scuffing of the seat material.

    6 All reflux valves shall be suitable for operating in the horizontal plane unless otherwise
    specified.

    7 Cover plates shall be of sufficient size to allow easy hand access for cleaning and service
    and shall be supplied complete with tapped bosses fitted with air release cocks.

    8 Valves above 350 mm bore shall be provided with feet.

    9 The design of the valve body shall be such that there is adequate clearance around and at
    the back of the door to minimise jamming by rags and debris. Stops shall be provided to limit
    the back lift of the door and shall be positioned to prevent fouling.
    QCS 2014 Section 08: Drainage Works Page 10
    Part 05: Valves, Penstocks and Appurtenances

    10 The hinge pin/shaft shall be stainless steel SS316 S31 and preferably square in section to
    ensure positive location of the door. If circular shafts are utilised the back flushing lever shall
    be located on a squared section, the diagonal dimensions of which shall be equivalent to the
    full diameter of the shaft. Both door and lever shall be positively and securely fixed to the
    hinge pin/shaft. Grub screws, pins (parallel to taper) or clamps will not be acceptable. All
    internal fixing devices shall be of stainless steel SS316 S31.

    11 Reflux valves fitted to the delivery side of pumps shall be fitted with balance weights to
    minimise slam. If specified, they shall be provided with a totally enclosed proximity switch
    operated by an external cam fitted to the extended spindle. The proximity switch shall be of
    the metal clad type with sealed actuator and cable entry. Cam operated micro-switches will
    not be acceptable.

    5.6 PLUG VALVES


    1 Plug valves shall be eccentric and equipped with resilient faced plugs and be of non-

    .
    lubricated type capable of handling abrasive and raw sewage. The plug valves shall have

    l
    .l.
    PN 16 flanged ends. Valves shall be furnished with manual operators as a unit. Each valve
    plug shall rotate 90 degrees from the fully open to the tightly shut position and shall seat at an

    rw
    angle of 90 degrees from the pipe axis in which the valve is installed.

    2 Valves shall be satisfactory for applications involving throttling service and for frequent

    ta
    operation after long periods of inactivity. Valves with operators shall be suitable for operation
    with flow in either direction.
    qa
    3 Valves shall be non-lubricated, with non-shock pressure differential acting in either direction;
    at 175 kPa differential across the valve, the valve will provide drip-tight shut-off. Valves
    as

    75 mm diameter and above shall have bolted bonnet design. Bodies shall be of high carbon
    cast iron or nickel iron having 1 % to 1.5 % nickel content. Valves shall have raised seats
    se

    and all surfaces in contact with the plug face shall have 90 % pure nickel or coating. Valves
    shall have an average tensile strength of 240 MPa. Port areas of valves sizes greater than
    100 mm shall be at least 75 % of full pipe area. Flanged valves shall be faced and drilled
    er

    minimum PN 16 standard and shall have face-to-face dimensions of standard sluice valves.
    ov

    Valves shall have balanced plugs to assure low torque and drip-tight shut-off.

    4 Valves shall be equipped with resilient plug facing to provide drip-tight shut-off without use of
    o

    sealing lubricants. Even if small solids are trapped between the plug and seat, the resilient
    facing shall provide tight shut-off and prevent seat damage. Resilient plug facings shall be
    it

    neoprene, ethylene propylene terpolymer, or other suitable materials capable of handling


    et

    abrasives and raw sewage.


    m

    5 Valves shall have heavy-duty upper and lower guide bearings capable of resisting corrosion
    and lubricated by the liquid being handled.

    6 Valves shall be actuated by means of lever for valves under 80 mm in size and by enclosed
    gear and handwheel operator for valves 100 mm and longer. All valves shall be supplied with
    operators which required less than 10 N/m torque for operation. Chain wheels with guides
    shall be furnished on all valves located 2 m or more above floor levels with stainless steel.

    7 Valves operating devices shall be as specified in Clause 5.12 herein.

    5.7 SURFACE BOXES


    1 Surface boxes and covers shall be adjustable cast iron of the slip type and fitted to the sizes
    and depths of valves as shown on the Drawings. Covers and frames shall be heavy duty and
    be suitable for wheel loads up to 11.43 tonnes.
    QCS 2014 Section 08: Drainage Works Page 11
    Part 05: Valves, Penstocks and Appurtenances

    2 Surface boxes shall be coated by dipping or other equivalent means using a hot applied coal
    tar based material complying with BS 4164 or cold applied bitumen material complying with
    BS 3416. No coating shall be applied to any casting until its surfaces are clean dry and free
    from rust oil and deleterious material.

    5.8 VALVE OPERATING TEE KEYS


    1 Valve operating keys shall have a 50mm square socket. The length of the key shall enable
    the valve to be operated with hands at waist height. Unless otherwise stated in the Contract
    Documents one tee key per ten valves that are to be tee key operated, shall be provided for
    each site.

    5.9 AIR VALVES


    1 Air and gas relief valves shall be of the double orifice pattern with grey or ductile cast iron
    bodies. The inlet flange shall be faced and drilled in accordance with BS EN 1092 PN16. Air

    l .
    valves for TSE or potable water shall be of the water type. Air valves for all other waste

    .l.
    water work shall be of the sewage type.

    rw
    2 The valve shall be adequately sized for the release of gas from the pipeline (or other
    container) without restriction of rate of filling or flow due to back pressure and also to allow
    admission of air during pipeline emptying at a rate sufficient to prevent excessive depression
    of pressure in the pipe.
    ta
    qa
    3 Valves shall be designed to prevent the operating elements being in contact with the pipeline
    liquid by approved means such as the provision of an auxiliary float and chamber sufficiently
    as

    large to isolate the orifice valves and seats throughout the rated operational range.

    4 In applications where the pipeline characteristics may lead to liquid column separation with
    se

    consequent possibility of surge a vented non-return valve shall be provided which allows air
    to enter freely on separation but controls explosion of air/gas as the liquid column re-joins.
    er

    5 In applications where the hydraulic conditions are such that pressures fall below atmospheric
    ov

    pressure during normal operation and where air inflow at that time could induce surge
    conditions, an air inflow check valve shall be incorporated.
    o

    6 All air and gas relief valves and associated isolating valves shall be works tested and capable
    it

    of withstanding the same test pressures as the pipeline or vessel on which they operate.
    et

    7 Air valves and operating linkages that are not made stainless steel shall be pure epoxy resin
    m

    coated in accordance with Part 8 of this Section.

    8 Air valves shall be vented wherever possible directly into the wet well. In cases where this is
    not possible the Contractor shall provide suitable odour removal for the air expelled from the
    valve.

    9 Where air may be drawn into the valve that contains dust, sand etc. means shall be provided
    for trapping/filtering this.

    10 Air valves shall be installed in such a manner that routine maintenance can be carried out.

    11 Air valves shall be fitted with an isolating sluice valves and gearing shall be provided where
    necessary to facilitate operation.

    5.10 PRESSURE CONTROL AND RELIEF VALVES


    QCS 2014 Section 08: Drainage Works Page 12
    Part 05: Valves, Penstocks and Appurtenances

    5.10.1 General

    1 The valve body shall be of cast iron conforming to BS EN 1561 with flanges conforming to
    BS EN 1092 PN16 or BS 10. The valve shall be extra heavy construction throughout. The
    valve interior trim shall be bronze as well as the main valve operation. All working parts shall
    be easily removed from the valve body for ease of maintenance. All controls and piping shall
    be of non-corrosive construction.

    5.10.2 Pressure Reducing Valves

    1 Pressure reducing valves shall maintain any desired downstream-delivery pressure for which
    the reducing pilot valve is adjusted provided the upstream head does not drop below a
    determined head. During low flow conditions, a resilient rubber valve seat shall ensure drop
    tight sealing. The valve shall be completely piped ready for installation.

    5.10.3 Pressure Relief Valves

    l .
    .l.
    1 Pressure relief valves shall maintain constant upstream pressure by bypassing or relieving
    excess pressure, and shall maintain close pressure limits without causing surges. The main

    rw
    valve shall be a hydraulically operated, diaphragm-actuated, globe or angle pattern valve. It
    shall contain a resilient, synthetic rubber disc. The downstream pressure setting shall be
    adjusted by compression of the spring via the adjusted screw.

    5.10.4 Pressure Regulating and Sustaining Valves ta


    qa
    1 Pressure sustaining valves shall open and close in modulating action as required to maintain
    constant system pressure. On pressure reversal valve shall close tightly. Operation shall be
    as

    completely automatic with only one adjustment required to change the pressure setting.
    Adjustable pressure range from 1.0 bar to 8.5 bar. The valve shall be "Y" pattern globe
    se

    diaphragm actuated with pilot control. The diaphragm shall be made of reinforced neoprene
    and the pilot shall be bronze and all tubing copper.
    er

    5.11 PENSTOCKS
    ov

    5.11.1 General
    o

    1 Each item of equipment shall be furnished and installed complete with all supports, anchor
    it

    bolts, stems, stem guides, and appurtenances ready for operation. All mechanisms and parts
    et

    shall be amply proportioned for the stresses which may occur during operation or for any
    other stresses which may occur during fabrication and erection. Individual parts furnished
    m

    which are alike in all units shall be alike in workmanship, design, and materials and shall be
    interchangeable. Penstock in sewage pumping stations shall be stainless steel/cast iron with
    gun metal seating suitable for corrosive environment.

    5.11.2 Cast Iron Penstocks

    1 Penstocks shall be suitable for their application, and shall be installed and positioned in such
    a manner as to allow ease of operation and maintenance.

    2 Penstocks shall carry identification marks and brass name plates in accordance with BS EN
    12334, which identify the penstock number and function.

    3 Penstocks shall be clockwise closing.

    4 Penstocks shall be watertight under the conditions stated for head and direction of flow.

    5 All materials used in manufacture of the penstocks shall conform to the following minimum
    standards unless otherwise specified:
    QCS 2014 Section 08: Drainage Works Page 13
    Part 05: Valves, Penstocks and Appurtenances

    Cast Iron BS EN 1561 Grade 250


    Gunmetal BS 1400 Grade LG2
    Aluminium Bronze BS 2872 Grade CA104
    Stainless Steel BS 970 Pt. 1 Grade 316 S31
    High Tensile Brass BS 2874 Grade CZ114
    (Manganese Bronze)
    Manganese Steel BS 970 Pt. 1 Grade ISOM19
    Phosphor Bronze BS 2574 Grade P13
    6 Fixing nuts and bolts supplied by the manufacturer shall be of stainless steel.

    7 Each penstock shall be provided with a suitable handwheel of adequate diameter for the duty
    required. Gearing shall be supplied where necessary:

    (a) to ensure that the required operating force applied by hand to the rim of the wheel
    does not exceed 250N (25Kgf)
    (b) if the handwheel cannot be readily accessed, extension spindles, headstocks and foot

    l .
    brackets shall be provided where specified

    .l.
    (c) where possible, the extension spindle shall be of the rising type with the threaded

    rw
    portion position above top water level
    (d) headstocks for non-rising spindle installations shall incorporate a position indicator.

    ta
    qa
    8 Handwheels shall have smooth rims and the direction of closing which shall be clockwise
    shall be cast on them. Vandal and weather proof clear polycarbonate tube covers shall be
    securely fitted to protect the threads of rising stems and spindles. Tubes shall be clearly and
    as

    permanently engraved to indicate the position of the valve.


    se

    9 The frames and doors of cast iron penstocks shall be made from close grained grey iron.
    The penstocks shall be designed so as to ensure tight closure while maintaining freedom of
    door movement during operation and minimising sliding wear of the sealing faces. They shall
    er

    incorporate adjustable wedges or swivelling cams and actuating pegs manufactured from a
    non-corrodible material.
    ov

    10 Headstocks and foot brackets shall be provided for non-rising spindle penstocks where the
    latter are specifically called for. Guide brackets shall however be provided where necessary.
    o

    Non-rising spindles shall be fitted with thrust collars and arranged so as to transmit the thrust
    it

    arising due to the operation of the penstock directly to the penstock frame. Where
    et

    headstocks are required on non-rising spindle installations they shall incorporate a penstock
    position indicator.
    m

    11 Penstock spindles shall be of forged stainless steel SS316 S31 , machined all over, with a
    machine cut robust trapezoidal or square form thread, operating in a gunmetal nut.

    12 Extension spindles shall be of stainless steel SS316 S31and shall be compliant with the
    requirements for penstock spindles. Extension spindle couplings shall be of the muff type
    and shall be drilled and provided with a nut and bolt for securing the spindle to the penstock
    spindle, which shall likewise be drilled to accept the bolt.

    13 Extended spindle installations of the rising type shall be provided for valves of 300 mm bore
    and above, and for all motorised/actuated penstocks. These shall be of stainless or
    manganese steel or manganese bronze. Thrust tubes shall be provided between the
    penstock from and headstock in order to absorb the thrust in both directions of operation.
    Thrust tubes shall incorporate all necessary fixing brackets and spindle guide plates. All
    handwheels, headstocks, foot brackets and guide brackets shall be of cast iron.
    QCS 2014 Section 08: Drainage Works Page 14
    Part 05: Valves, Penstocks and Appurtenances

    14 Where penstocks are required to be operated by tee keys, spindle caps shall be fitted. The
    caps shall be drilled and each provided with nut and bolt for securing to the spindle which
    shall likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied
    complete with operating tee key. The extended spindle shall be such that the tee key will be
    operated at 0.9-1.2 metres above floor level.

    15 Where penstocks are provided with greasing nipples, these shall be fitted with extension
    tubes to facilitate lubrication from a nearby walkway or other readily accessible location.

    16 Non-ferrous metal sealing faces shall comprise accurately machined gunmetal or bronze
    strips bedded and fixed to machined recesses in the frame and door. The strips shall be
    secured by non-corrodible countersunk screws. The faces of the strips shall then be brought
    together in the operation position and hand scraped to a watertight finish.

    17 Handwheels, headstocks, foot brackets and thrust tubes shall be of cast iron.

    .
    18 Cast iron penstocks and headstocks shall be coal tar epoxy coated in accordance with Part 8

    l
    .l.
    of this Section.

    rw
    5.11.3 Stainless Steel Penstock

    1 Where indicated on the drawings or elsewhere in the Contract Documents, penstocks for use

    ta
    in aggressive environments shall be manufactured from corrosion resistant materials as
    follows:
    qa
    (a) Metal parts exposed to the atmosphere shall be manufactured from stainless steel to
    BS 970 Part 1, Grade 316 S31.
    as

    (b) The frame shall be fixed to the wall using nuts and bolts Grade 316 S31 stainless
    steel.
    se

    (c) The door of the penstock shall be manufactured from corrosion resistant plastic or
    stainless steel (Grade 316 S31). Plastic shall also be totally resistant to ultra-violet
    er

    light. Asbestos shall not be used in any filling materials within plastic gates.
    ov

    (d) The seals used on corrosion resistant penstocks shall be suitable for the medium in
    which the penstock is immersed. Flexible rubber seals shall not be used on penstocks
    immersed in raw sewage for example, where sharp objects and grit may destroy the
    o

    seal at the high velocities experienced when opening and closing the doors.
    it

    2 All other requirements shall be as specified in Clause 5.11.2 herein.


    et

    5.11.4 Plastic Penstocks


    m

    1 Plastic penstocks shall be of the flush invert type and the underside sealing face shall consist
    of high resilient material securely bonded into a channel or similar section forming the invert
    of the frame into which the bottom of the door shall effect a watertight seal.

    2 The door of plastic penstocks shall be made from sheets of approved rigid cellular polymer
    sandwiched between sheets of approved rigid compressed composite plastics. The linear
    PVC or GRP materials shall be used. The doors thus formed shall have sufficient strength to
    withstand the required working pressure without deflection or distortion that would affect the
    operation of water-tightness of the penstock. Totally enclosed steel matrix shall be
    incorporated in the door construction to ensure adequate rigidity.

    3 The sealing faces and side guides shall be EPDM having a high resistance to sliding wear
    and shall be to the approval of the Engineer. The sealing strips shall be securely fixed to the
    inner faces of the frames and adjusting devices or other means of ensuring freedom of
    movement without loss of seal shall be provided. The adjusting devices and fasteners shall
    be of stainless steel conforming to BS 970 Part 1 Grade SS 316 S31.
    QCS 2014 Section 08: Drainage Works Page 15
    Part 05: Valves, Penstocks and Appurtenances

    4 Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra-high


    molecular weight polyethylene material. The operating nuts for the spindle retaining blocks
    shall be fixed in a visible position inside a separate gate lifting bracket bolted on to the top of
    the door with stainless steel fasteners. The operating nut or spindle retaining block shall not
    be contained within the door.

    5 All plastic materials shall be non-toxic ultraviolet stabilised and shall have fire resistance as
    specified in BS 475 and be to Class P and Class I of Part 5 and 7 thereof respectively.

    6 All other requirements shall be as specified in Clause 5.1.3 Clause 5.11.2 herein.

    7 Plastic penstocks shall only be used when indicated in the Contract Documents and
    approved by the Engineer.

    5.11.5 Stoplogs

    .
    1 Stoplogs shall be fabricated from reinforced composite plastic material which is non-toxic and

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    stabilised against ultraviolet light. Asbestos shall not be used in the manufacture of the stop-
    logs.

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    2 Plastic logs of 300 mm and 400 mm depths shall be furnished to provide closure of stoplog
    openings. Full depth gates shall not be acceptable.

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    Each log shall be provided with a stainless steel eye bolt at each end which fits into a recess
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    in the under surface of the next log. Two lifting poles fitted with hooked ends for engaging
    the eye bolts shall be furnished for each facility and shall be mounted locally on a handrail
    supported pole rack. Poles and racks shall be constructed of aluminium and bolts of
    as

    stainless steel.
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    4 Stoplogs shall provide a high degree of sealing with a leakage rate of less than 0.04 l/sqm of
    seating perimeter. Stoplog frame shall be for insertion in a wall and invert recess.
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    5 Anchor bolts shall be stainless steel.


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    6 Frames shall be manufactured from stainless steel BS 970 or BS 1449 Grade 316. All frames
    shall be suitably reinforced and include corner gussets where necessary. All fasteners shall
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    be stainless steel.
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    7 Frames shall be fitted with seals which are molecularly incompatible with the closure
    et

    material. Where necessary, the seals shall be fixed with corrosion resistant retaining strips
    and stainless steel fasteners.
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    5.12 OPERATING DEVICES

    5.12.1 Lifts

    1 Lifts shall be designed to operate the gate of the specified head with a maximum of 25 kg
    force applied to the device. The lift shall be a liftnut for tee key operation or gear/handwheel
    lift as designated.
    QCS 2014 Section 08: Drainage Works Page 16
    Part 05: Valves, Penstocks and Appurtenances

    5.12.2 Liftnut

    1 The liftnut shall be hexagonal, gunmetal and internally threaded to fit the stem. The housing
    shall be cast iron and suitable for mounting in the head angle, gate frame extension or wall
    mounted bracket. The liftnut shall be flanged to maintain position in the housing and to
    accommodate the thrust developed during gate operation. Each lift shall be furnished with a
    bronze stop nut. The nut lift shall accept a T-bar operator or handwheel. Suitable T-bar
    operators shall be furnished.

    5.12.3 Gear Lift

    1 The gear lift mechanism if required shall be of the crank operated type with either a single or
    double gear ratio, depending on the lift load. Each type shall have a cast bronze liftnut
    threaded to fit the operating stem. Ball thrust bearings shall be provided above and below
    the flange on the liftnut to take the load developed in opening and closing the gate. Gears
    shall be of cast iron or steel, accurately machined with cut teeth, and smooth running with

    .
    suitable shafts running in gunmetal sleeve bearings or roller bearings of ample size. All

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    geared lifts shall be suitable for auxiliary motor operation. All gears and bearings shall be
    enclosed in a cast iron housing. Fittings shall be provided so that all gears and bearings can

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    be periodically lubricated. The removable cast iron crank shall be fitted with a rotating
    handle. The lift mechanism shall be supplied with a cast iron pedestal, machined and drilled
    to receive the gear housing and suitable for bolting to the thrust tubes, operating floor or wall

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    bracket. The maximum crank radius shall be 400 mm. The direction of rotation to open the
    gate shall be indicated on the lift mechanism. A cast iron stop nut shall be provided for each
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    lift. All exposed cast iron shall be coated according to Part 8 of this section.

    5.12.4 Handwheel
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    1 The housing shall be cast iron and shall be suitable for mounting on the head angle or pipe
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    frame extension. The lift nut shall be flanged to maintain position in the housing and to
    accommodate maximum thrust developed during gate or valve operation. The lift nut shall
    be bronze and internally threaded to mate the stem. Each lift shall be furnished with a bronze
    er

    stop nut. The steel or cast iron handwheel shall have a solid rim and shall be smooth and
    free of sharp edges and an arrow and the work "OPEN" shall be cast in the rim or attached to
    ov

    the handwheel. Handwheels generally shall be positioned on a headstock 750 mm above


    operating level.
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    5.12.5 Stem Covers


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    1 Stem covers shall be provided on all valves or gates with rising stems. Stem covers shall be
    clear butyrate with Mylar decals indicating open and close gate position and of sufficient
    m

    length to totally enclose the stem when the gate is fully open. The top shall be closed and
    the bottom shall screw into a cast iron housing mounted on top of the gate operator. The
    inside of this housing shall be bored to the exact diameter of the stem cover to assure
    accurate alignment of the cover.

    5.12.6 Actuators

    1 Actuators are specified in Section 21.


    QCS 2014 Section 08: Drainage Works Page 17
    Part 05: Valves, Penstocks and Appurtenances

    5.13 FLAP VALVES

    5.13.1 Flap Valves (General Purpose)

    1 The seat shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with a raised
    section around the perimeter of the waterway opening to provide the seat. The raised
    section shall provide a seating plane diverging, top to bottom, from the plane of the mounting
    flange to assist in positive closure of the cover. The seat shall be shaped to provide two
    bosses extending above the top of the waterway opening for mounting the top pivot lugs.
    Pivot lug bosses shall be drilled and tapped for mounting studs. The flap shall be designed
    to be either butted to the face of a wall or to the outlet flange of a discharge pipe. The flaps
    shall be operable at a head of 10 m.

    2 The cover shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with
    necessary reinforcing ribs, with a lifting eye for manual operation, and with bosses to provide
    a pivot point connection with the links. Bosses shall be designed to place the hinge bolts in

    .
    double shear when gate is assembled.

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    3 Each pivot lug shall be one-piece cast iron. Lugs shall have double bosses to place the top

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    hinge bolts in double shear when they are assembled through the links. The lugs shall be
    adjustable in the horizontal plane without removal of the cover from the gate links. The
    adjustment shall allow the top pivots to be moved toward the gate seat for reduced sensitivity

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    of the cover, or moved away from the gate seat to provide opening with a minimum
    differential head. Two studs shall be used to connect each pivot to the gate seat.
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    4 The links connecting the cover and pivot lugs shall be one-piece heavy duty cast iron. Each
    link shall be provided with bronze bushings at each pivot point. The bottom of the links shall
    as

    be provided with an adjusting screw to properly align seating faces on the cover with respect
    to the seat. The links shall be designed to limit the double hinge action, preventing the cover
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    from rotating sufficiently to become wedged in the open position.


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    5 Cast iron work shall be coated before delivery with a bituminous compound as specified in
    Clause 8.5.16.2 of QCS.
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    5.13.2 Flap Valves for Sea Water Applications


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    1 Flap valves frames including fixings for sea water and other aggressive applications shall be
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    of stainless steel conforming to BS 970 Part 1. Sealing faces shall be phosphor bronze
    conforming to BS 2874.
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    2 Flap valves manufactured from corrosion resistant materials will also be acceptable for
    general purpose applications.

    3 Flap valves above 1500 mm square shall be of the double door type.

    4 Doors shall be of reinforced natural rubber compound of sufficient flexibility to maintain an


    efficient seal under minimal seating head conditions.

    5 Door hinges shall be continuous across the full width of the door and manufactured from
    homogeneous polypropylenes, polyurethane or similar non-ageing material.

    5.14 MISCELLANEOUS VALVES AND APPURTENANCES

    5.14.1 Ball Float Valves

    1 Ball float valves shall comply with BS 1212. Flanges shall conform to BS EN 1092.
    QCS 2014 Section 08: Drainage Works Page 18
    Part 05: Valves, Penstocks and Appurtenances

    2 PVC ball valves 50 mm and smaller shall be of the true union socket weld type, and valves
    75 mm and larger shall be of the flanged type. Valves shall be rated at 1000 kPa at 50 C
    unless otherwise specified.

    3 Metal ball valves 60 mm and larger shall have brass balls with carbon steel bodies, and
    valves 50 mm and smaller shall have brass bodies. Valves shall have a Teflon seal and
    seat. Valves shall be rated at 1000 kPa at 100 C unless otherwise specified.

    4 Stainless steel ball valves shall be flanged with stainless steel body, ball and stem. Valves
    shall be rated at 1000 kPa at 100 C unless otherwise specified.

    5.14.2 Globe Valves

    1 Globe valves shall be low-zinc bronze body type with tapered discs permitting close
    regulation of flow. Valves 75 mm and larger shall be flanged, Class 125 conforming to ANSI
    B16.1 in drilling and dimensions. Valves 60 mm and smaller shall be 1,000 kPa, and shall

    .
    have screwed joints.

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    5.14.3 Quick Coupling Valves

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    1 Quick coupling valves shall be of robust construction consisting of a cast bronze body and
    dust cap with machined bronze valve cage and seat. The valve washer shall be neoprene

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    rubber with stainless steel packing washer and fixing screw. The stem seal ring shall be
    neoprene rubber.
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    2 Double lug keys with swivel hose ells and standard 20 mm diameter hose connectors of the
    same manufacturer shall be supplied to the Employers stores at the rate of one key for every
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    five hose points. Each part shall be cast or machined bronze with neoprene rubber seals.
    The cost of supplying these keys complete shall be included in the rates for valves.
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    5.14.4 Emitters
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    1 Bubble emitters shall be brass with 12 mm BSP thread designed for adjustable flows.
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    5.15 FITTINGS
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    1 All flanges, fittings, coupling, valves, and appurtenances shall be rated for the pipeline
    et

    pressure, except as noted on the Drawings.


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    5.15.2 Flanges, Gaskets, and Bolts

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

    5.16 MECHANICAL COUPLINGS


    QCS 2014 Section 08: Drainage Works Page 19
    Part 05: Valves, Penstocks and Appurtenances

    5.16.1 Grooved End Couplings

    1 Couplings shall engage and lock the grooved or shouldered pipe ends allowing some degree
    of contraction, expansion, and angular deflections. Coupling housing shall be of ductile iron
    or malleable iron and shall consist of two or more segments held securely together by at least
    two steel bolts. Sealing gasket shall be of such design that internal pressure in the pipe
    increases the tightness of the seal and shall be of materials suitable for the intended service.
    The coupling shall have a rated working pressure not less than the pressure rating of the
    pipe.

    2 Corrosion protection shall be applied in accordance with the requirements specified in Clause
    5.16.2 herein.

    5.16.2 Flexible Couplings

    1 Flexible (sleeve) couplings of the full sleeve type, split sleeve type, or flanged adapter type

    .
    shall provide the requisite pipe flexibility without jeopardising pipe joint integrity due to

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    hydraulic thrust, and shall have the same pressure rating as the pipe. Couplings shall have
    all metal bearing surfaces and shall be provided with galvanised steel bolts and nuts.

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    Flexible couplings shall be restrained unless the Engineer has given his approval to omit this
    feature for specific cases. Specific requirements for each type are as follows:

    (a)
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    full sleeve type couplings shall be properly gasketed and shall be of a diameter to
    fit the pipe. Each coupling shall consist of a steel middle ring, two steel followers, two
    qa
    gaskets, and the necessary steel bolts and nuts to compress the gaskets. Stepped
    couplings of this general type shall be used when stepping from one pipe material to
    another of the same nominal diameter
    as

    (b) split sleeve type couplings shall consist of one gasket, two housing clamps, and two
    bolts and nuts to obtain the flexibility for connecting the piping. Steel shoulders shall
    se

    be provided and welded to the pipe ends to accommodate the couplings


    (c) flexible flanged coupling adapters shall be of the sleeve type, consisting of steel
    er

    middle ring, steel followers, gaskets, and steel bolts and nuts to compress the
    gaskets. The couplings shall contain anchor studs of strength adequate to hold the
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    pipes together under a pull equal to the longitudinal strength of the pipes.

    2 Couplings to be installed underground shall, in addition to any factory applied paint coating,
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    site have one of the following corrosion protection systems:


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    (a) hot pour moulding with enamel complying with BS 4164 type IV Grade 105/8, to give
    et

    a minimum of 20 mm thickness around all parts of the fittings


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    (b) laminate tape coating after priming and profiling with mastic
    (c) paint coating with high build coal tar mastic to give a minimum dry film thickness of
    500 m in at least three coats.

    3 Step couplings used in force mains with flexible pipes shall be provided with a restraint
    system where necessary to prevent longitudinal movement between the flexible pipe and the
    coupling. The restraint system shall be as shown on the Drawings or approved by the
    Engineer.

    4 No joints shall be coated until hydrostatic testing of the joints is successfully completed.

    5.17 FLOW CONTROL

    5.17.1 Vortex Flow Control Devices

    1 Where indicated on the drawings or elsewhere in the Contract Documents, Vortex Flow
    Control Devices shall be manufactured from corrosion resistant materials as follows:
    QCS 2014 Section 08: Drainage Works Page 20
    Part 05: Valves, Penstocks and Appurtenances

    (a) stainless steel to BS 970 Part 1, Grade 316 S31.


    (b) the device shall be fixed using nuts and bolts of Grade 316 S31 stainless steel.

    5.18 INSTALLATION AND TESTING

    5.18.1 Installation

    1 The Contractor shall obtain the necessary installation drawings from the manufacturer and
    shall store, transport, handle and install the valves, penstocks, stoplogs, and appurtenances
    in strict accord with the manufacturers drawings and recommendations. Care shall be taken
    during mounting of gates and logs to avoid warping the frames and to maintain clearance
    between seating faces.

    2 All ferrous surfaces shall be finish coated in accordance with Part 8 of this Section.

    5.18.2 Testing

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    1 Factory Testing. Penstocks shall be factory-tested for a seat clearance check in accordance

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    with the applicable provisions of AWWA C501. Penstocks that do not conform with the
    testing requirements of AWWA C501 shall be made satisfactory or rejected and replaced.
    Before shipment of the gates, the Contractor shall submit certified copies of test reports to
    the Engineer for review.
    ta
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    2 Site Testing. Following completion of the installation of the penstock, the Contractor shall
    furnish the services of the authorised representative of the manufacturer to adjust and
    operate the gates of directed by the Engineer. Adjustment shall be made so that the gates
    as

    operate smoothly, seat properly, and are installed to the tolerances recommended by the
    manufacturer. After the equipment has been tested and adjusted, the Contractor shall
    perform a field leakage test on each gate in the presence of the Engineer in accordance with
    se

    the applicable provisions of AWWA C501. Both seating and unseating heads shall be tested
    as applicable. If any of the equipment fails to meet the above test, it shall be modified as
    er

    required and retested to conform with specifications, until the maximum allowable leakage,
    per AWWA C501, is not exceeded. Modifications or adjustments required to meet the test
    ov

    shall not impair the smooth operation of the equipment.


    o

    END OF PART
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    QCS 2014 Section 08: Drainage works Page 1
    Part 06: Miscellaneous Metal Works

    6 MISCELLANEOUS METAL WORKS ............................................................. 2

    6.1 GENERAL ...................................................................................................... 2


    6.1.1 Scope 2
    6.1.2 Reference 2
    6.1.3 Submittals 2
    6.1.4 Quality Assurance 3
    6.1.5 Delivery, Storage and Handling 3
    6.2 MATERIALS .................................................................................................. 4
    6.2.1 Steel 4
    6.2.2 Stainless Steel 4
    6.2.3 Aluminium 4

    .
    6.2.4 Iron 4

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    6.2.5 Welded Anchor Studs 4

    rw
    6.2.6 U Channel Concrete Inserts 4
    6.2.7 Concrete Anchors 5
    6.3
    6.3.1 Galvanising ta
    COATINGS .................................................................................................... 5
    5
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    6.3.2 Anodising 6
    6.3.3 Factory Painting 6
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    6.4 FABRICATION AND ERECTION ................................................................... 7


    se

    6.4.1 General 7
    6.4.2 Staircases 8
    er

    6.4.3 Ladders 9
    6.4.4 Step Irons 10
    ov

    6.4.5 Handrails and Railings 10


    6.4.6 Chequer Plate 11
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    6.4.7 Gratings and Open Mesh Flooring 12


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    QCS 2014 Section 08: Drainage works Page 2
    Part 06: Miscellaneous Metal Works

    6 MISCELLANEOUS METAL WORKS


    6.1 GENERAL

    6.1.1 Scope

    1 This part includes the specifications for the design, fabrication and erection of ladders,
    staircase assemblies, open mesh flooring, chequer plate, gratings, handrailing, step irons,
    supports, anchors, and other appurtenances.

    2 Related Sections and Parts are as follows


    This Section
    Part 1, General
    Part 3, Pipes and Fittings Materials

    .
    Part 7, Miscellaneous GRP Works

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    Part 8, Protective Coatings and Painting

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    Section 1, General
    Section 16, Structural Metalwork
    Section 17, Metalwork.
    6.1.2 Reference ta
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    1 The following standards or revised/updated versions are referred to in this Part:
    as

    BS 970........... Wrought steels for mechanical and allied engineering purposes


    BS 1470......... Wrought aluminium and aluminium alloys for general engineering purposes;
    se

    plate, sheet and strips


    BS 1471......... Wrought aluminium and aluminium alloys for general engineering purposes;
    er

    Drawn Tube
    BS 1472......... Wrought aluminium and aluminium alloys for general engineering purposes;
    ov

    forging stock
    BS 1474......... Wrought aluminium and aluminium alloys for general engineering purposes -
    o

    bars, extruded round tube and sections


    BS 4211......... Specifications for permanent fixed ladders
    it
    et

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


    BS 5395......... Stairs, ladders and walkways
    m

    BS 5493......... Code of practice for protective coating of iron and steel structures against
    corrosion

    BS EN 1561... Founding Gray Cast Iron


    BS EN 1563... Found spheroidal graphite cast iron
    BS EN 1993... EURO code 3, Design of steel structures
    BS EN 13101. Manhole steps
    BS EN ISO 2560 Welding consumables - Covered electrodes for manual metal arc welding
    of non-alloy and fine grained steels

    EN 124 .......... Gully tops and manhole tops for vehicular and pedestrian areas Design
    requirements, type testing, marking, quality control
    ISO 9000 ....... Quality System
    6.1.3 Submittals

    1 The Contractor shall submit complete data as described below.


    QCS 2014 Section 08: Drainage works Page 3
    Part 06: Miscellaneous Metal Works

    2 Product Data:

    (a) the Contractor shall provide manufacturers specifications, load tables, dimension
    diagrams, anchor details and installation instructions for products to be used in the
    manufacture of metal fabrications.

    3 Design Calculations and Shop Drawings:

    (a) the Contractor shall provide design calculations and shop drawings for the
    fabrication and erection of all assemblies of metal fabrication work which are not
    completely shown by manufacturers data sheets, including anchorage and accessory
    items. Plans and elevations at metric scales not less than 1:10 scale, and details of
    sections and connections at not less than 1:5 scale shall be included
    (b) detailed drawings shall show material type, thickness grade/class dimensions, and
    construction scheme. The submittal shall include catalogue pages, erection
    description, manufacturers data/instructions and templates.

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    4 Where structural steelwork is to be provided the Contractor shall submit duplicate copies of
    dimensioned shop drawings for approval by the Engineers Representative. If drawings are

    rw
    not approved, one copy shall be returned to the Contractor marked up indicating the
    alterations required. Upon final approval one copy of the drawing, stamped Approved by the
    Engineers Representative, shall be returned to the Contractor. Four further copies of the
    ta
    approved drawings shall then be submitted to the Engineers Representative. No shop
    qa
    fabrication may commence before receipt of the relevant shop drawings.

    5 The shop drawings shall become record drawings on the completion of steelwork erection
    as

    and the original drawing and one ISO size A2 (495 & 420) negative of each shall be supplied
    to the Engineer. If there were any changes to the steelwork during erection these should be
    supplied together with the original and the size A2 signed negative.
    se

    6 WPS and PQR


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    6.1.4 Quality Assurance


    ov

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

    approval of the Engineer.


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    2 Where welding/brazing is required the Contractor shall:


    m

    (a) submit for approval welding procedure specification (WPS) and procedure qualification
    record (PQR) in conformance with AWS D1.1(steel structures), ASME IX (piping and
    pressure vessels) and BS EN 288 part 4 (Aluminium) and BS EN ISO 1101-8 (Iron) as
    appropriate;
    (b) submit for approval welder qualifications which shall be in conformance with the above
    codes and or BS EN ISO 9606-2 (aluminium alloys),
    (c) assign a CSWIP 3.1 or AWS QC qualified welding inspector, who shall be subject to
    the Engineers approval, to witness all welding.

    6.1.5 Delivery, Storage and Handling

    1 Metal works shall be stored off the ground, protected from moisture, until ready for use or
    installation.

    2 Metal works shall be stored and handled in such a manner to protect finishes.

    3 Metal works shall be stored and handled to prevent bending under its own weight and
    superimposed loads.
    QCS 2014 Section 08: Drainage works Page 4
    Part 06: Miscellaneous Metal Works

    6.2 MATERIALS

    6.2.1 Steel

    1 Steel rolled shapes, plates and bars shall conform to the requirements of Section 16 unless
    otherwise specified in this Part.

    2 Bolts and nuts shall be of standard commercial quality steel conforming to Section 16, and
    shall be galvanised when used with galvanised work.

    AWS D 1.1 - Steel Structure Welding Code


    ASME VIII Div. 1 - Pressure Vessel welding
    ASME IX - Boiler & Pressure Vessel Code - Section IX Welding & Brazing
    ASME B31.3 - Process Pipe
    6.2.2 Stainless Steel

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    1 Stainless steel shall conform to BS 970 and shall be Grade 316 S31 unless otherwise
    designated.

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    2 Stainless steel bolts, hexagonal cap screws, and studs shall be BS 970 Grade 316 S31
    unless otherwise designated.
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    qa
    3 All stainless steel to be welded shall be BS 970 Grade 316L.

    6.2.3 Aluminium
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    1 All aluminium plate, pipe and structural shapes shall conform to BS EN 12020, and BS 1472
    with BS EN 485 Grades 6036-T6 or 6082-T6 or such other chemically resistant alloy that the
    se

    manufacturer can demonstrate to be suitable for use in aggressive atmospheres likely to be


    encountered in sewage pumping stations. All aluminium items embedded in concrete shall
    er

    have two coats of bituminous paint. Where aluminium surfaces are in contact with concrete
    surfaces or with dissimilar metals, PVC-U gaskets shall be used to isolate the aluminium.
    ov

    6.2.4 Iron
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    1 Ductile Iron. Ductile iron shall be in accordance with BS EN 1563.


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    et

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


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    3 Malleable Iron. Malleable iron shall be in accordance with BS EN 13101.

    6.2.5 Welded Anchor Studs

    1 Headed anchor studs (HAS) or threaded anchor studs (TAS), as indicated on the Contract
    Drawings:

    (a) Carbon Steel: BS EN ISO 898, either semi-killed or killed aluminium or silicon
    dioxidation, unless indicated otherwise.
    (b) Stainless Steel: BS EN ISO 3506, Grade SS 316, Condition CW, where indicated.

    6.2.6 U Channel Concrete Inserts

    1 Rolled: BS EN ISO 9445 Type 316 stainless steel, 2.7 mm thickness, 40 mm width by 35
    millimetres depth, with stainless steel anchors at 250 mm maximum spacing, Styrofoam
    fillers, and end cap.
    QCS 2014 Section 08: Drainage works Page 5
    Part 06: Miscellaneous Metal Works

    2 Nut and Bolt Hardware: Type 316 stainless steel, 16 mm minimum diameter, unless
    indicated otherwise. Manufacturers standard to match insert.

    6.2.7 Concrete Anchors

    1 For concrete anchor spacing less than 12 anchor diameters and edge distances less than
    six anchor diameters, make reduction in allowable pullout and shear values.

    2 Allow for thermal movement resulting from the maximum range in ambient temperature in
    design, fabrication, and installation of handrails to prevent buckling, opening up of joints, over
    stressing of components, connections and other detrimental effects. Base design calculation
    on actual surface temperatures of materials due to both solar heat gain and night time sky
    heat loss. Temperature change is difference between high or low temperature and
    installation temperature.

    3 Use approved service load allowable values for size, length, embedment, spacing, and edge

    .
    distance to match required loads shown in calculations.

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    6.3 COATINGS

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    6.3.1 Galvanising

    1
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    Galvanising shall be executed after all fabrication has been completed and shall be carried
    qa
    out in accordance with BS 5493:1977. The articles shall be pickled in dilute sulphuric or
    hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They shall be
    thoroughly washed, stoved and dipped in molten zinc and brushed so that the whole of the
    metal shall be evenly covered and the coating thickness after dipping shall not be less than
    as

    the BS 5493 System Reference Number recommended for the particular conditions and in
    any case not less than 85 microns.
    se

    2 Unless otherwise specified, all ferrous metals shall be galvanised in conformance with
    er

    reference standards according to the nature of the work. Factory fabrication shall be
    complete before galvanising. Galvanised coatings that have been marred or damaged
    ov

    during erection or fabrication shall be repaired using designated touch-up material.

    3 Surfaces of exterior units which have been galvanised after fabrication and are intended for
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    bolted or screwed field connections shall not be welded, cut or abraded.


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    et

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


    conforming to BS 5493 and in accordance with the coating manufacturer's instructions.
    m

    5 Unpainted galvanized surfaces shall not be used in an immersed condition within three
    months of hot dip galvanizing and/or before an adequate protective patina has formed.

    6 All mild steel parts unless otherwise stated, are to be heavily galvanised by the "hot dip"
    process, or other methods as agreed by the Engineer, after fabrication. Where large units are
    concerned, an approved metal spraying process to BS specifications may be used subject to
    the approval of the Engineer. With the exception of the metal flooring to be supplied
    unpainted, the whole of the galvanised mild steel parts and metal sprayed parts are to be
    treated with a zinc phosphate primer before leaving the place of manufacture. (No lead oxide
    or iron may be used in priming the galvanised parts.) Painting shall be in accordance with
    the Schedule A [Work Requirements], Part 5 [Warranted Project Data], 5.1 [Drawings] or as
    selected by the Engineer.
    QCS 2014 Section 08: Drainage works Page 6
    Part 06: Miscellaneous Metal Works

    7 All steel and ironwork of whatever kind to be galvanised shall be thoroughly de-scaled by shot
    blasting to clear metal to BS 4232 second quality, to clean the surfaces of all dirt, weld
    spelter, grease, slag, oil-paint or other deleterious materials, and immediately after is to be
    galvanised by a hot dip process, followed by quenching in water. The molten zinc in the
    galvanising bath shall contain not less than 98.5 percent of zinc by weight. All articles are to
    be immersed in the bath only for a time sufficient for them to attain the temperature of the
    bath and they are to be withdrawn at such a speed that a coating of 90 microns thickness is
    achieved, or such other practicable maximum thickness for the article defined in BS 729, Part
    "Hot dip galvanised coating on iron and steel." The galvanising is to be done in all cases after
    machine work, chipping, trimming, filling, fitting, drilling or bending is completed. Every article
    is to be covered evenly on all sides.

    8 The zinc coating shall consist of a uniform layer of zinc free from abrasions, creeks, blisters,
    chemical spots or other imperfections, and so applied that it will adhere firmly to the surface
    of the steel.

    .
    9 The galvanising shall be applied in such a manner that the spelter will not peel off. The

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    coating of the finished product shall be even, smooth and uniform throughout. Machine work,
    dye work, cutting, punching, bending, welding, drilling, thread cutting and other fabrication

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    shall all be done, as far as practicable, before galvanising.

    10 The galvanising shall have no adverse effect on the mechanical properties of the articles so

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    treated. Variations in dimensional properties shall be kept to a minimum.
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    11 The work of surface preparation and galvanising shall be carried out, for any one article, on
    the same working day.
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    12 Galvanising on steelwork where required is to be carried out after fabrication and assembly.
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    13 Light gauge metal work is to be galvanised by the hot dip process as specified in BS 3083 or
    BS 2989.
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    14 Contact between galvanised steel members and aluminium surface is to be prevented by


    means of a layer of "Densochrome" or similar approved tape.
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    15 All necessary care and precautions are to be taken in shipping and transporting the
    galvanised or metal sprayed units to avoid damage to the coating. Where damage proves to
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    be extensive in the opinion of the Engineer, the whole unit shall be recoated.
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    16 Where galvanised parts are to be bolted or riveted together, the joint shall be made with an
    approved barium or zinc chromate paste.
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    17 Where the metal parts are too big to be hot dip galvanised, approval of the Engineer shall be
    sought for the steel parts to be shot blasted to BS 4232 second quality and then immediately
    zinc sprayed to a minimum thickness of 0.1 mm in accordance with BS 2569 Part 1.

    6.3.2 Anodising

    1 All aluminium members shall be anodised after fabrication in accordance with Sections 16
    and 17.

    2 All aluminium and aluminium alloy materials shall be anodised after fabrication to a thickness
    of grade AA 20 and subsequently sealed against corrosion. After anodising, the aluminium
    surfaces shall not be painted but left self-finish. Anodising of aluminium shall comply with the
    requirements of BS 1615.

    6.3.3 Factory Painting

    1 All protective coatings and painting shall be carried out as specified in Part 8 of this Section.
    QCS 2014 Section 08: Drainage works Page 7
    Part 06: Miscellaneous Metal Works

    2 Before leaving the factory, ferrous metals not designated to be galvanised shall be given one
    coat of primer as specified in Clause 8.2 of Part 8. Portions to be embedded in concrete or
    masonry shall not be painted.

    6.4 FABRICATION AND ERECTION

    6.4.1 General

    1 Stairs, ladders and walkways provided shall conform to BS 4211 and BS 5395.

    2 Fabrication and erection shall be performed by approved specialist subcontractors


    experienced in work of equivalent magnitude. Shop drawings shall be prepared by the
    Contractor based on the details shown on the Drawings. The Contractor shall

    (a) verify all measurements and shall take all site measurements necessary before
    fabrication

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    (b) be responsible for correctness of detailing, fabrication, and for the correct fitting of

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    structural members

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    (c) not substitute sections
    (d) not modify connections.

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    Members and connections, for any part of the structure, not shown on the Drawings shall be
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    the Contractors responsibility.
    3 The Contractor shall use materials of the size and thickness shown on the Drawings, or if not
    as

    shown, of the required size and thickness to produce adequate strength and durability in the
    finished product for the intended use.
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    4 All work at the factory shall be preassembled to the greatest extent possible to minimise field
    splicing and assembly of units at the Site. Units shall be disassembled only to the extent
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    necessary to comply with transportation limitations and shall be clearly marked for
    reassembly and proper installation. Ladders shall be supplied as preassembled units.
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    5 For the manufacture of metal fabrications which will be exposed to view, only materials which
    are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled
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    trade names and roughness shall be used. Any such blemishes shall be removed by
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    grinding, or by welding and grinding, before cleaning, treating and application of finishes
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    including anodising and galvanising. Smoothness shall be required all round for handrails
    and ladders.
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    6 Exposed work shall be formed true to line and level with accurate angles and surfaces and
    straight sharp edges. Exposed edges shall be rounded to a radius of approximately 1 mm
    unless otherwise designated.

    7 Exposed connections with hairline joints which are flush and smooth shall be formed using
    concealed fasteners wherever possible. Exposed fasteners shall be flat-head (countersunk)
    screws or bolts. Bolt and screw holes shall be predrilled for attachment of metal fabrication
    work and for the attachment of adjacent materials.

    8 Welding shall be carried out by experienced tradesmen, and made with designated
    electrodes or submerged arc conforming to BS EN ISO 2560. The following procedures shall
    be carried out:

    (a) before fabrication, all steel shall be thoroughly wire brushed, clean of all scale and
    rust, and thoroughly straightened by approved methods that will not injure the
    materials being worked on
    QCS 2014 Section 08: Drainage works Page 8
    Part 06: Miscellaneous Metal Works

    (b) welding shall be continuous along the entire line of contact except where tack or
    intermittent welding is permitted
    (c) where exposed, welds shall be cleaned of slag and ground smooth.
    (d) All stainless steel welding shall be gas tungsten arc welding (GTAW)or shield metal
    arc welding (SMAW) processes using stainless steel type 316L consumables
    conforming to the requirements of the under-mentioned codes / AWS A5.9 (GTAW) or
    AWS A5.4 (SMAW).
    (e) All aluminium welding shall be undertaken using GTAW process using consumables
    under 5356 classification of AWS A5.10.
    (f) Welding to be undertaken in accordance with the applicable code as follows:
    General guidance for arc welding BS EN ISO 1101 1
    Arc welding of ferritic steels BS EN ISO 1101 2
    Arc welding of stainless steels BS EN ISO 1101 3
    Arc welding of aluminium BS EN ISO 1101-4

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    Welding of cast iron BS EN ISO 1101 -8

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    Steel Structures AWS D1.1

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    Pressure vessels ASME VIII Div 1
    Piping ASME B31.3
    9 Fixing shall be carried out as follows:
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    (a) the Contractor shall fabricate and install anchoring devices with spacing as required
    to provide adequate support for the intended use of the work
    (b) fastenings to wooden plugs will not be permitted
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    (c) All nuts and bolts shall be threaded in accordance with BS 3643 Isometric series
    threads part 2 Limits and tolerances for coarse pitch threads and fitted with 3mm
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    thick washers beneath bolt and nut.


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    (d) Regardless of the materials being fixed all bolts, nuts, washers and anchor plates shall
    be of stainless steel Grade 316 S31 to BS 970 and shall remain unpainted. PTFE
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    washers shall be fitted beneath stainless steel washers for both bolthead and nut.
    (e) Drilled anchor fixings for use on concrete structure shall be of a type approved by the
    Engineers Representative. The positions of all drilled anchors shall be approved by
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    the Engineers Representative and any Contractor proposing to use such fixings shall
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    be deemed to have undertaken to supply, mark off, drill and fit.


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    (f) All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be
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    such that when fitted with a nut and tightened down, the threaded portion shall fill the
    nut and not protrude from the face thereof by more then half the diameter of the bolt.
    (g) All jointing material shall be provided by the Contractor.

    10 Dissimilar materials shall be separated by gaskets.

    6.4.2 Staircases

    1 Metal staircases shall be constructed to the overall dimensions detailed on the Drawings and
    shall be prefabricated in marine quality mill finished aluminium alloy or galvanised steel.
    Staircases shall be designed to span longitudinally from wall to wall and shall be designed to
    carry a live load of 5 kPa. Stringers shall be of adequate size to support dead and live loads.

    2 Treads shall be of non-slip surface and shall have adequate stiffness to carry a point load of
    1.8 kN at the centre.

    3 Landings shall not exceed 3 m.


    QCS 2014 Section 08: Drainage works Page 9
    Part 06: Miscellaneous Metal Works

    4 Kicker plates shall extend to a minimum of 100 mm above flooring and open sides. The
    risers shall not exceed 200 mm.

    5 Chequer plates shall be as specified in Clause 6.4.6 wherein.

    6 Unless otherwise shown on the Contract Drawings, furnish flush type abrasive nosing on
    stairs.

    7 Nosing Components:

    (a) Homogeneous epoxy abrasive, with minimum 50 percent aluminium oxide content,
    formed and cured upon an extruded aluminium base.
    (b) Epoxy abrasive shall extend over and form curved front edge of nosing.
    (c) Base of Nosing: Extruded aluminium alloy, 6063-T5, heat-treated complying with BS
    EN 12020.

    .
    (d) Anchoring System: Double-set anchors consisting of two rows of integrally extruded

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    anchors.

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    (e) Size: 75 mm wide by 6 mm to 10 mm thick by length as shown.
    (f) Colour: Selected by Engineer from manufacturers standard colour range.

    6.4.3 Ladders
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    qa
    1 Galvanised steel ladders shall be to the form and dimensions shown on the Drawings, and as
    specified below:
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    (a) ladders shall comply with BS 5395, Part 3.


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


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


    (e) rungs shall be
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    (i) solid sections of minimum 20 mm diameter


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    (ii) at 300 mm centres


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    (iii) minimum 380 mm wide between stringers


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    (iv) minimum 200 mm from adjacent walls


    (v) capable of withstanding a point load of 5000 N applied at the centre of the rung
    and close to one end
    (f) when supported horizontally over a span of 1.0 m with the climbing face uppermost
    and with a load of 1000 N applied at the centre of the span, the ladder shall not
    deflect more than 15 mm at the point of application of the load and shall show no
    permanent deflection after removal of the load. Each ladder fixing shall be capable of
    withstanding shear and pull-out loads of 5000 N
    (g) safety cages shall be provided where indicated and where the distance between
    landings exceeds 3500 mm. These shall be constructed of three vertical flat sections,
    minimum size 50 mm by 8 mm supported by flat hoops with a diameter of 750 mm.
    The hoops shall be at a maximum of 900 mm centres and the first hoop shall be
    2400 mm above lowest platform level. No single hoop shall be used
    QCS 2014 Section 08: Drainage works Page 10
    Part 06: Miscellaneous Metal Works

    (h) all welds shall be ground flush and smoothed and ladders hot-dip galvanised after
    fabrication. Connections to concrete or masonry walls shall be secure with accurately
    positioned stainless steel anchor bolts. Ladders shall be mounted to produce a
    finished appearance that is plumb, straight and true to dimensions.

    2 Stainless steel ladders shall generally be of dimensions as designated for galvanised steel
    ladders except that all materials shall be of stainless steel.

    3 Aluminium ladders shall be to the form and specified dimensions shown on the Drawings,
    and as specified below:

    (a) the spacing of stringers, rungs and safety hoops shall be as galvanised steel ladders.
    (b) material shall be aluminium alloy to BS EN 573 grade EN AW-6082.
    (c) ladders shall be of all welded construction. Stringers shall be drilled to receive rungs
    which shall be welded into position from the outside of the stringers. Welds shall not
    be proud of the outside of the stringers

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    (d) rungs shall be of substantial section serrated tube to enable sure hand and foot holds
    (e) fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy

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    from other materials
    (f) all other requirements shall be as specified for galvanised steel ladders
    (g)
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    ladders shall be obtained from approved suppliers.
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    6.4.4 Step Irons

    1 Step ironing rising main valve chambers shall be galvanised malleable cast iron, shall
    as

    conform to BS EN 13101, and shall be of general purpose type. The tail length shall be 230
    mm unless the well into which the tail is to be cast is less than 290 mm thick.
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    2 Step irons in house connection chambers shall comply with BS EN 13101 and be the
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    general-purpose type manufactured of galvanised malleable cast iron. The tail length shall be
    115mm. The step irons shall be epoxy coated with a material compatible with a galvanised
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    surface and finished with a two part, acrylic polyurethane topcoat as detailed below and
    applied in accordance with the manufacturers instructions.
    Epoxy Coating 50 DFT
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    50 DFT
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    Two Part Acrylic Finish


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    6.4.5 Handrails and Railings


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


    GRP, circular hollow section, marine quality mill finished aluminium alloy (BS EN 573 grade
    EN AW-6082) in pre-fabricated lengths complete with fixings or shall be stainless steel
    circular hollow section (BS970 Grade316S31). Site welding will not be accepted. All welded
    parts to be completed during manufacturing fabrication with approved WPS by Engineer in
    accordance with Clause 6.1.4 of this Part. Handrails and railings fabricated from mild steel,
    stainless steel, or aluminium as shown on the Drawings and meet the following requirements:

    (a) brackets, bolts and fastening devices shall be provided as required for
    complete installation
    (b) handrailing and railings shall be provided with smooth bends and welded joints
    ground smooth and flush
    (c) installed railings and supports shall withstand a 1100 N load applied at any point,
    downward or horizontally or 740 N/m along the top rail, whichever is greater
    (d) the deflection of both rails and standards shall to exceed 2 % of the span/height under
    a horizontal load of 360 N/m on the top rail.
    QCS 2014 Section 08: Drainage works Page 11
    Part 06: Miscellaneous Metal Works

    2 Galvanised steel handrailing shall be provided in accordance with the following requirements:

    (a) stanchions shall have a nominal bore of 40 mm and a minimum wall thickness of
    3.25 mm
    (b) stanchions on steel stringers shall have base plates or angles welded to bottom of
    pipe and bolted to stringer
    (c) rails shall have a nominal bore of 32 mm and minimum wall thickness of 4 mm
    (d) horizontal handrails shall be 1,100 mm high with an intermediate rail 550 mm high
    (e) railings shall be
    (i) mounted so as to produce a finished appearance that is plumb, straight, and
    true to dimension, free from kinks, twists, and abrasions
    (ii) curves, where indicated on the Drawings or necessary, shall be bent to a radius

    .
    of not less than 100 mm. Where shown on the Drawings, or directed by the

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    Engineer, removable sections shall be provided

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    (f) toe plates shall be provided where railings are not mounted on stanchions

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