Contents

1 INTRODUCTION ................................................................................................................ 7
2 SCOPE OF WORK............................................................................................................... 8
3 DESIGN CRITERIA.............................................................................................................. 9
3.1 Ambient Conditions ........................................................................................................... 9
Temperature .............................................................................................................................. 9
Rainfall........................................................................................................................................ 9
Humidity..................................................................................................................................... 9
3.2 Life of Plant ........................................................................................................................ 9
3.3 Material Handled ............................................................................................................. 10
4 STANDARD ..................................................................................................................... 11
4.1 Australian Standard.......................................................................................................... 11
4.2 Indonesian Standards....................................................................................................... 12
4.3 International Standards ................................................................................................... 12
5 TECHNICAL REQUIREMENT.............................................................................................. 13
5.1 Structural Steelwork......................................................................................................... 13
5.1.1 General..................................................................................................................... 13
5.1.2 Supervision............................................................................................................... 13
5.1.3 Inspection................................................................................................................. 13
5.1.4 Material – General ................................................................................................... 14
5.1.5 Testing of Material ................................................................................................... 14
5.1.6 Shop Drawings.......................................................................................................... 15
5.1.7 Fabrication ............................................................................................................... 16
5.1.8 Marking .................................................................................................................... 17
5.1.9 Bolt holes.................................................................................................................. 17
5.1.10 Connection and Details ............................................................................................ 17
5.1.10.1 Bolt Surface Treatment .................................................................................... 18
5.1.10.2 Bolted Connections .......................................................................................... 18
5.1.11 Welding .................................................................................................................... 20
5.1.11.1 General............................................................................................................. 20
5.1.11.2 Qualification ..................................................................................................... 21
5.1.11.3 Procedure......................................................................................................... 21
5.1.11.4 Quality .............................................................................................................. 22

Page 3 of 60
 5.1.11.5 Butt Welds........................................................................................................ 22
5.1.11.6 Fillet Welds....................................................................................................... 23
5.1.11.7 Welding Electrodes and Welding Plant............................................................ 23
5.1.11.8 Weld Testing..................................................................................................... 23
5.1.11.9 Non-Destructive Testing of Welds ................................................................... 23
5.1.12 Gridmesh Flooring.................................................................................................... 24
5.1.13 Platforms, Walkways, Stairways and Ladders.......................................................... 24
5.1.14 Monorails ................................................................................................................. 26
5.1.15 Inspection................................................................................................................. 26
5.1.15.1 Responsibility ................................................................................................... 26
5.1.15.2 Inspection during fabrication ........................................................................... 26
5.1.15.3 Inspection prior to transportation ................................................................... 27
5.1.15.4 24 hours notice of inspection........................................................................... 27
5.1.16 Handling, Delivery to Site and Storage .................................................................... 27
5.1.17 Erection .................................................................................................................... 27
5.1.18 Grouting of Base Plates............................................................................................ 29
5.1.19 Surface Coatings....................................................................................................... 29
5.1.19.1 Surface Preparation.......................................................................................... 29
5.1.19.2 Protective Coating............................................................................................ 30
5.2 Concrete Work ................................................................................................................. 31
5.2.1 Extent of Work ......................................................................................................... 31
5.2.2 General Requirements ............................................................................................. 31
5.2.3 Supervision............................................................................................................... 31
5.2.4 Inspection................................................................................................................. 32
5.2.5 Materials for Concrete ............................................................................................. 32
5.2.5.1 Cement ................................................................................................................. 32
5.2.5.2 Aggregates............................................................................................................ 32
5.2.5.3 Water ................................................................................................................... 33
5.2.5.4 Admixtures ........................................................................................................... 33
5.2.5.5 Steel Reinforcement............................................................................................. 34
5.2.5.6 Site Mixing............................................................................................................ 35
5.2.5.7 Measurement of Materials .................................................................................. 36
5.2.6 Supply of Concrete ................................................................................................... 36

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 5.2.7 Quality of Concrete .................................................................................................. 37
5.2.8 Stabilised Sand ......................................................................................................... 37
5.2.9 Preparation of Surface before Placing of Blinding ................................................... 37
5.2.10 Concret Blinding Layer ............................................................................................. 38
5.2.11 Formwork and Falsework......................................................................................... 38
5.2.12 Formwork Ties.......................................................................................................... 39
5.2.13 Preparation of Formwork Surfaces before Placing of Concrete .............................. 40
5.2.14 Placing of Concrete .................................................................................................. 40
5.2.15 Pumping ................................................................................................................... 41
5.2.16 Finish of Concrete Surfaces...................................................................................... 42
5.2.17 Tolerances for Floor Surfaces................................................................................... 43
5.2.18 Construction Joints................................................................................................... 43
5.2.19 Curing of Concrete ................................................................................................... 44
5.2.20 Sampling and Testing ............................................................................................... 45
5.2.21 Rejection of Concrete............................................................................................... 46
5.2.22 Removal of Formwork.............................................................................................. 46
5.2.23 Core Holes and Building-In....................................................................................... 47
5.2.24 Anchor Bolts ............................................................................................................. 48
5.2.25 Joint Fillers................................................................................................................ 48
5.2.26 Joint Sealants ........................................................................................................... 49
5.2.27 Water-stops.............................................................................................................. 49
5.3 Piling................................................................................................................................. 50
5.3.1 Extent of Works........................................................................................................ 50
5.3.2 Foundation Information........................................................................................... 50
5.3.3 Materials .................................................................................................................. 51
5.3.3.1 Concrete ............................................................................................................... 51
5.3.3.2 Reinforcement...................................................................................................... 51
5.3.3.3 Admixture............................................................................................................. 51
5.3.4 Pile Capacity and Pile Set ......................................................................................... 51
5.3.5 Construction Requirements ..................................................................................... 52
5.3.5.1 Drilling .................................................................................................................. 52
5.3.5.2 Reinforcing ........................................................................................................... 53
5.3.5.3 Concreting ............................................................................................................ 53

Page 5 of 60
 5.3.6 Pile Splicing............................................................................................................... 54
5.3.7 Pile Toe Levels – Pile Acceptance............................................................................. 55
5.3.8 Pile Driving Plant ...................................................................................................... 55
5.3.9 Handling of Piles....................................................................................................... 56
5.3.10 Marking .................................................................................................................... 56
5.3.11 Pitching and Driving ................................................................................................. 56
5.3.12 Tolerances ................................................................................................................ 57
5.3.13 Driving Record.......................................................................................................... 57
5.3.14 Defective or Damaged Pile....................................................................................... 58
5.3.15 Pile Cut-Off ............................................................................................................... 58
5.3.16 Dynamic Pile Testing ................................................................................................ 58
6 Contractor Supplied Drawings and Data .......................................................................... 60
6.1 As-Built Drawings ............................................................................................................. 60
6.2 Drawing Format ............................................................................................................... 60

Page 6 of 60
1 INTRODUCTION
This specification covers the minimum technical requirements of all operation in connection
with supply, fabrication, transport, erection, inspection and testing of structural work.

The work described under this specification includes the supply of all materials and
construction of all structural works in accordance with the contract drawings and this
specification.

Any specific requirements additional to those set out in this specification will be found in the
accompanying drawings and/or the job specification.

The work shall be carried out strictly in accordance with:

- The conditions, requirement, schedules and drawings contained in the contract

- Any variation and / or modification agreed to by Principal and the contractor.

This contract is for the supply of structural steelwork for the project mentioned above with
the requirement detailed on the following sections.

Page 7 of 60
2 SCOPE OF WORK
This specification details the construction requirements for strcutural works including
steelwork, concrete work and pilling to be complete on the Asiatic Coal Terminal Project.

The work described under this specification includes the supply of all metarial and
construction of all structural works in accordance with the contract drawings and this
specification.

Page 8 of 60
3 DESIGN CRITERIA
3.1 Ambient Conditions
All components supplied under this contract shall be suitable for continuous operation 24
hours per day 360 days per year. The equipment will be exposed to the following ambient
conditions:

Temperature

Throughout the year typical

- Average monthly temperature : 25 deg. C

- Mean daily temperature : 22 – 30 deg. C
- Average monthly relative humidity : 80 – 90%
- Evaporation rate (approximately) : 4 mm/day

The equipment shall operate continuously at the nominal capacities exposed to the
following ambient temperature.

- Mean daily maximum temperature : 30 deg. C

- Maximum daily operating temperature : 40 deg. C
- Mean daily minimum temperature : 23 deg. C

Rainfall

- Mean annual precipitation : over 2,000 mm

- Mean number of days with precipitation : 175 days per year
- Maximum recorded rainfall in 24 hour period : 118 – 310 mm
- Wettest months: November to December typically more than 350mm rainfall per
month.
- Driest month: May through July with typically less than 200mm rainfall per month.

Humidity

- Minimum humidity : 60%

- Maximum humidity : 95%
- Average
: 85%

3.2 Life of Plant

The design life of plant is 25 years. For equipment selection and design, the facility shall be
designed for continuous duty, 24 hours per day

Page 9 of 60
3.3 Material Handled
Material properties for the materials handled in this project are as follows:
a. Material conveyed : Crushed coal
b. Maximum lump size : -50mm
c. Size distribution : 95% minus 50mm with minimum fine
d. Bulk density
 For volume and handling rate calc : 0.8 t/m³
 For load, power, and structural calc : 1.1 t/m³
e. Repose angle : 37°
f. Material conveying surcharge angle : 15°
g. Total moisture : 40.4%
h. Inherent moisture : 17.1%
i. Ash content : 4.2%
j. Volatile matter : 42%
k. Fixed carbon : 36.7%
l. Total sulphur : 0.77%
m. Grindability (HGI) : 39 min – 56 max (45 average)
n. Air temperature : 23 °C (min) - 40°C (max)

Page 10 of 60
 # Special Note)
The supplier shall apply other code & standard as per "A4.
Deviation Code & Standard" instead of Australian Standard.
4 STANDARD
The following standards shall be made the basis for this Specification. The works shall comply
with all Statutory Regulations, appropriate codes of practice and relevant standards to such
work in Indonesia.

The design, supply, manufacture, inspection, testing and delivery of the Equipment shall
comply with Standards, Regulations, and Codes. The following documents shall apply unless
otherwise approved by the Company:

4.1 Australian Standard

Standard Description

AS 1012 Method of testing concrete

AS 1111 ISO Metric Hexagon Bolts and Screws
AS 1112 ISO Metric Hexagon Nuts
AS 1163 Structural Steel Hollow Sections
Hot-dip galvanized coatings on threaded fasteners
AS 1214
(ISO metric coarse thread series)
High-strength Steel bolts with associated nuts and
AS 1252
washers for structural engineering
AS 1289 Methods of testing soils for engineering purposes
Geometric product specification (GPS) – Indication of
AS 1302
surface texture in technical product documentation
AS 1379 Specification and supply of concrete
AS 1478 Chemical admixtures for concrete, mortar and grout
AS 1553 Covered Electrodes for Welding
AS 1554 Structural Steel Welding
Metal Finishing-Preparation and pre-treatment of
AS 1627
surfaces
Fixed Platform, Walkways, Stairways, and Ladders –
AS 1657
Design, Construction, and Installation
Non-destructive testing – Ultrasonic testing of carbon
AS 1710 and low alloy steel plate and universal section – Test
methods and quality classification
AS 2074 Cast Steel
Non-destructive testing-Radiography of welded but
AS 2177
joins in metal
Page 11 of 60
 Standard Description

AS 2350 Methods of testing portland and blended cements

Specification for general-purpose flexible PVC
AS 2571
compounds for moulding and extrusion
AS 2758 Aggregates and rock for engineering purposes
Supplementary cementitious materials for use with
AS 3582
portland and blended cement
AS 3678 Structural Steel – Hot-rolled plates and slabs
AS 3679 Structural Steel
AS 3600 Concrete structures
AS 3610 Formwork for concrete
AS 4100 Steel Structures
AS 4671 Steel reinforcing materials
AS 60974 Arc welding equipment

4.2 Indonesian Standards

Standard Description

Tatacara perencanaan Ketahanan Gempa untuk

SNI-1726
Struktur Bangunan Gedung
Tatacara Perencanaan Struktur baja untuk Bangunan
SNI-1729
Gedung
Baut Kepala Segi Enam untuk Kontruksi dengan
SNI 05-0541
kekuatan tinggi

4.3 International Standards

Standard Description

ISO 9001 Quality Management Systems

Quality systems-Model for quality assurance in production,
ISO 9002
installation and servicing

Page 12 of 60
 # Special Note)
The supplier shall apply other code & standard as per "A4.
Deviation Code & Standard" instead of Australian Standard.
5 TECHNICAL REQUIREMENT
5.1 Structural Steelwork
5.1.1 General
The work comprised under this section of the specification includes the supply,
fabrication, delivery to site and erection of all structural steelwork complete as shown on
the drawings and as necessary for the completion of the work.

The supervision, workmanship and tolerances in fabrication and erection of structural of

steelwork shall be in accordance AS4100, together with all other relevant standards
referred to therein, except where varied by this specification or the drawings.

This specification generally refers to Australian Standards. Where applicable the

contractor may substitute Australian Standards with an approved equivalent.

5.1.2 Supervision
The contractor shall employ foremen experienced in all facets of steel fabrication,
erection and welding, whose sole responsiblity shall be the supervision of structural
steelwork for this contract.

The contractor shall also employ on site an experienced welding supervisor whose sole
responsibility shall be to ensure that correct aand approved welding procedures are
followed for all welded connections.

5.1.3 Inspection
During fabrication the Contractor shall permit the Superintendent or his representative
free access to the fabricator’s works at reasonable times for the purpose of carrying out
inspection and shall afford all necessary facilities for the carrying out of such inspections.

Unit shall be laid out and fabricated as necessary so that all parts are accesible for
inspection before transportation to the site.

Where steel has been inspected by the superintendentat the works before being
delivered to the site, such inspection shall not relieve the Contractor of his responsibility
to provide correct fitting together on erection and all steel shall be subject to final
approval after erection in place.

Any inspection by the superintendent shall not prevent the ultimate rejection of any
works or materials in which defects have been found at any time prior to the completion
of the contract.

All welding included in this contract is subject to inspection by a Welding Inspector who
will work under the direction of the superintendent.

The Welding Inspector’s scope of duties and privileges shall be as specified in AS1554.

Page 13 of 60
 The appointment of a welding inspector by the superintenedent shall not relieve the
contractor of his responsibility to properl supervise and carry out quality control over all
works carried out either in the workshop or on site.

Notwithstanding the provisions of AS1554, the sole authority for final determination of
quality of and adequacy of welds shall be the superintendent.

5.1.4 Material – General

All material used shall be new and free from defects. All structural steel shall be ASTM
A36 or better.
All steel used in this contract shall be hot rolled structural grade steel manufactured by the
open hearth, Basic Oxygen (LD) or Electrical Furnace processes. Unless specified
otherwise herein, or on the drawings, steel of Grade 250 to the equivalent of AS3678 and
AS3679 shall be used. The Contractor may propose alternative steel grades to suit local
market availability. The Contractor shall submit of alternative steel grades to the
superintendent.
All structural steel plates and rolled sections shall conform to the requirements of AS3678
and AS3679. Hollow section shall conform to the requirements of AS1163. Steel castings
shall conform to the requirements of AS2074.
If steel sections shown on the Drawings are not readily available within indonesia, the
Contractor may propose the use of alternative sections which shall have section properties
not less than those for the members specified.
The Contractor shall obtain Manufacturer’s Certificates for all steel plate and sections
demonstrating compliance in all respects with the specified standards. Manufacturer’s
Certificates shall be submitted and the written approval of the superintendent obtained
before fabrication work commences. All such plates and sections shall have clear and
distinct marks identifying the respective grades of steel.
Material taken from stock to be used for the structural members must be of a quality at
least equal to that required by this spesification.
The Contractor shall maintain mill test reports covering the materials intended to be used
for the works.
Unidentified steel shall not be used in structural members.
All steel shall be free from excessive rust, pitting and other defects which either impair the
structural capacity of the member or are likely to impair the quality of the protective coating
system.
All steel sections shall be roll-straightened if necessary before fabrication into a structural
member. Materials that have been split or permanently injured shall not be used.

5.1.5 Testing of Material

The Contractor shall be responsible for maintaining quality control over the chemical
analysis and mechanical properties of all steel for use in the works. Chemical analysis and
mechanical testing, including tension, bend, flattening and impact test, shall be
performed for each batch of steel. Testing shall be performed by the steel manufacturer
or by an approved labooratory. Result shall be presented in a manner which

Page 14 of 60
 demonstrates compliance to the requirements of the relevant Autralian Standard and
shall be made available for inspection by the superintendent when requested.

All steel plates 32 mm thick and over which are intended to be used in the work shall be
tested ultrasonicaly for flaws, lamination and other defects. Test certificates for each
plate so tested shall be submitted and approval of the Superintendent obtained before
fabrication work commences.

Interpretation of the results of non-destructive testing shall be in accordance with

AS1554. Non-destructive testing shall be carried out in accordance with AS2177 for
Radiography examination and AS1710 for Ultrasonic testing.

All non-destructive testing for which the contrator is reponsible shall be performed by a
testing authority which has been approved by the superintendent.

5.1.6 Shop Drawings

The Contractor shall initially supply to the superintendent two (2) copies of all such shop
details.

Shop drawings shall show all material, sizes, dimension, marking of parts, weld
preparation, bolt holes, connections, protective coatings and shall set out the position,
size and lengths of all welds necessary for the complete fabrication, assembly and
erection of the structural steelwork.

All splice and joints shall be shown and detailed on the shop drawings. The Shop Drawings
shall also show all cleats, fixings and the like required for the fixing of architectural
fittings.

The Contractor’s marking plans shall be submitted in the first batch of shop drawings and
updated issue shall be progressively supplied as required to enable examination of the
drawings to proceed. Each shop drawing shall be provided with all information required
for checking without reference to other drawings.

The detail will be reviewed by the superintendent for member size, surface treatment and
adequacy structural connections only. When the details have been examined, one copy
shall be returned bearing the Superintendent’s endorsment. The Contractor shall
resubmit drawings requiring correction.

After shop drawings have been reviewed by the Superintendent and corrected where
necesarry, the contractor shall submit two (2) final copies of all such drawings to the
Superintendent for his use.

Shop Drawings are to be submitted in suitable sized batches to facilitate chechking by the
Superintendent. Shop drawings shall be returned to the contractor bearing the
superintendent’s endrosement and comments within seven (7) working days of their
submission.

Page 15 of 60
 The Contractor shall verify all dimension from the site and shall be responsible for the
same and any discrepancies in the drawings shall be brought to the attention of the
superintendent before fabrication commences.

While detail have been prepared with due regard to all reasonable requirements as to
practicability of fabricating, transporting and erecting to the required tolerances, it shall
remain the responsibilty of the the contractor to check the clearances for transportation
and for erection, entry beetwen gussets and attachments, the ability to erect to the
required tolerances, and other matters affecting erection and to amend any details on his
shop drawings in order to comply with these requirements. Should any such be of a major
nature, the contractor shall report them to the superintendent before making such
alterations.

The submission of the shop details will be taken as an acceptance by the contractor of the
practicability of fabricating and erecting the structure to the required specification and
tolerances.

The Contractor shall be responsible for all errors in the Shop Drawings. All error in
fabrication which result from errors in the Shop Drawings shall be corrected by the
Contractor at his expense including any reworking of incorrectly fabricated item.

5.1.7 Fabrication
The fabrication of all steelwork shown shall be carried out in accordance with the
requirements of AS4100 and welding shall be in accordance with the requirements of this
technical specification and the Drawings.

In addition, except where otherwise specified and/or shown, fabrication shall generally
conform to the methods and recommendations set out in “A Manual for the Design and
Contsruction of Structural Steelwork, Part 8-Fabrication”, prepared by the Australian
Institute of Steel Construction and published by the Standards Association of Australia
(SAA MA1.8).

All member shall be fabricated true to shape and size, without distortion and with all
necessary provisions for handling, field splicing, field welding and the like.

All cutting and shearing shall be neatly done and all portions exposed to view shall be
neatly finished with all sharp edges ground off to a minimum radius of 1.5 mm.

Any plate or section injured by hammer marks or otherwise marked or defacted shall be
rejected.

Care shall be taken at all times when welding so as to ensure soundness.

Field splices, where not shown on the Drawings, but required by the Contractor for
fabrication, handling, transportation or erection reasons, shall be slearly shown on the
shop drawings. The locations of all such field splices are subject to the approval of the
superintendent. Adjoining members shall be match marked as necessary, and joined on
Page 16 of 60
 site by qualified complete penetration butt weld, the procedure and preparation for
which shall be submitted with and shown on the shop drawings. All such welds shall be
completely tested by non-destructive means. The location of all field splices shall be
shown on the As-Build Drawings.

5.1.8 Marking
All parts shall be properly marked to ensure that they are erected in the correct position
and orientation. Marking shall be by means of punch stencils having characters at least
12mm high. Splice plates, cleats and other small pieces required in marking field
connection shall be temporarily fixed to their respective members for delivery. Welding of
mark numbers will not be permitted on exposed surfaces of any members.

The weight of all major members of weight greater than two tonnes shall be marked on
the shop drawings and on the members.

Items or parts fabricated from other than structural grade mild steel shall be marked for
identification.

Where structural steelwork is to receive an approved surface treatment after fabrication

and before erection the marking shall be made in such a manner that the item may be
identified at all times and scribe lines and levelling marks readily located.

Loose piece for connections shall be attached to their respective members. Bolts, where
not in holes, shall be metal tagged, each type and size in a separate container.

5.1.9 Bolt holes

Holes for bolts shall be not more than 2mm larger in diameter than the bolt used. Holes
for anchor bolts shall be not more than 6mm oversize. Slotted holes shall be used unless
shown on the design drawings. Where slotted holes are specified or shown, such holes
shall be accurately shaped with sides smooth and parallel.

Round or slotted holes shall not be flame cut. The areas around holes shall be smooth and
free of burrs and fins or other defects which may present solid seating of the contact
surfaces.

Close tolerance bearing bolts shall have diameter of holes to the nominal diameter of the
bolt shank with a tolerance of minus 0 and plus 0.13mm.

Holes may be punched to at last 3mm undersize and then reamed to full zise. Punching of
holes full size shall be carried out in accordance with Section 5 of AS 1511 – High Strength
Structure Bolding Code.

5.1.10 Connection and Details

Shop connections shall be welded, and field connections shall be bolted, unless otherwise
shown on the Design Drawings. All bolting and welding shall conform AS 1250, and the
following requirements.

Page 17 of 60
 Connections between members shall, where practicable, be fabricated along the
guidelines of the drawing of standardised Structural Connections.

The Contractor shall supply all connection materials for both temporary and permanent
connections.

Where specifically detailed to be used, flexible end plates shall be continuously welded to
webs and flanges of members.where angle cleats are used they shall be continuously
welded.

Welded end plates and web cleat angles shall be free from such distortion as will prevent
the connected faced from being in full contact when bolted snug tight.

Where bolted end cleats are used, they, and the member to which they are connected
shall receive the full specified protective treatment before assembly.

5.1.10.1 Bolt Surface Treatment

All bolts, washers and nuts shall have an anti-corrosion treatment comprising one of the
following system:

a. Hot-dip galvanized in accordance with AS 1214.

b. Cadmium plated in accordance with AS 1790 (Classification Col.2)
c. Zinc plated in accordance with AS 1789
d. Treatment after assembly – normal finish (uncoated) prior to assembly. Exposed
surface of bolts, buts and washers subsequently anti-corrosion treated as specified
for the connected structural steelwork.

The choice of the above anti-corrosion treatments will be as shown on the Design
Drawings or otherwise speciified. If no system is specified on the Design Drawings the
Contractor shall request notification of the required system from the Company.

5.1.10.2 Bolted Connections

Unless specified otherwise herein or on the drawings bolts used for his contract shall be:

High Strength Structural Bolts – Grade 8.8/S for all bolts 16mm diameter and larger
connecting all structural steelwork.

Commercial Grade Mild Steel Bolts – Grade 4.6/S for all bolts less than 16mm diameter.

Commercial grade mild steel bolts shall be cold forged or hot forged swaged head bolts
and shall conform to the requirements of AS1111. Normal Hexagon nuts for commercial
grade bolts shall conform to the requirements of AS1112 Grade 4.6.

High strength structural bolts, nuts and washers shall conform to the requirements of
AS1252.

Page 18 of 60
All commercial grade bolts and high strength structural bolts, nuts and washers shall be
hot-dip galvanised in accordance with AS1214 and coated with suitable lubricant to
facilitate the initial tightening.

Unless specifically called for on the drawings, all bolts shall be tightened to the “snug
thight” conditions as specified elsewhere herein.

All holes for bolts shall be drilled full size, or where permitted by AS4100 or AS4100,
punched full size. Burnt holes will not be permitted under any circumstances.

After assembly of the parts to be joined, all holes shall be true troughout, perpendicular
to the face of the member and aligned so as to permit the bolts to be positions without
damage to threaded portion.

Contacting surfaces of parts being joined shall be free from distortion and all burrs or
ridge shall be removed.

The length of each bolt shall be such that the threaded portion will project through the
nut for at least one complete thread and such that the nut will be at least one threat
apart from the thread run-out.

The Shanks of all bolts shall be of sufficient length so that the thread shall not project
through the shear plane.

At least on washer but not more than two washers shall be placed under the part being
rotated in tightening. Taper washers shall be used where the part under the bolt haed is
not perpendicular to the axis of the bolt. Where possible, bolts shall be positioned so
that the tapers washers, if required, shall be fitted under the non-rotating part.

Bolts subject to tensile loads and bolts subject to severe vibration, and including all bolts
carrying crane and/or hoist loads, shall be locked in position in a manner approved by
the superintendent.

Installation of Bolts Used in Snug Tight Condition

Commercial grade bolts and high strength structural bolts used in the “snug tight”
condition shall be tightened so that the joined parts shall be firmly drawn together using
a standart ring spanner or podge spanner or a calibrated torque or pneumatic impact
wrench.

The bolts shall not be overstressed and the applied torque shall not exceed that
recommended by the bolt manufacturer. In no case shall the bolt tension exceed 65
percent or be less than 50% of tthe guaranteed yield load of the bolt.

Bolts shall not be used to force fit the abutting material together and any lack of fit shall
be referred to the superintendent who shall determine the action to be taken. Bolt holes
shall not be enlarged by flame cutting, but shall be reamed to the required size.

Page 19 of 60
 Installation of High Strength Friction Grip Bolts

where indicated on the drawings only, bolts shall be installed in a fully tensioned
condition designated 8.8/TF or 8.8/TB. Mating surfaces in a TF connection shall not be
painted after abrasive blast cleaning and shall be covered to prevent corrosion prior to
installation.

High strength structural bolt, nuts, washers and load indicating devices for friction grip
type connections shall be forged and heat treated and shall conform to the
requirements of AS1252.

High strength bolts, nuts, washers and load indicating devices shall be stored and
handled in the work, in transit and on the site in a manner that will prevent damage,
contamination, corrosion, or loss of the lubricant.

All high strength bolts for friction grip connections shall be assembled and tensioned
strcitly in accordance with AS4100.

Unless otherwise approved by the superintendent, all high strength bolts shall be
tensioned using the part-turn method. Match making shall be permanent, preferably
made with a heavy centre punch.

With prior approval of superintendent, the torque control method may be used for
tensioning high streng bolts. All torque wrenches or pneumatic impact wrenches used
for tensioning shall be calibrated on site at least once per shift, as specified in AS4100.

Where approved by the superintendent, load indicating devices installed strictly in

accordance with the manufacturer’s instruction may be used for tensioning high
strength bolts. Load indicating devices shall have a zinc sherardised finish.

High strength bolt which have been fully tensioned once shall not be retightened.

5.1.11 Welding

5.1.11.1 General
All welding shall conform to the requirements of AS 1554 in addition to other special
requirements noted on the Drawing and in this Specification.

All welders, welding supervisors and welding inspectors are to be qualified in

accordance with AS 1554, Part 1.

The contractor shall submit for approval details of all welding procedures. Approval by
the superintendent shall not relieve the contractor of his responsibility for the suitability
of any welding procedures and for the satisfactory execution of the work. Welding
procedures shall be such as to minimise distortion and restraint.

Intermittent welds will not be permitted. All interfaces between connecting steelwork
shall be continuouly welded and fully sealed.
Page 20 of 60
 Unless otherwise shown on the drawings, all welds shall be Qualified and Structural
Purpose (SP) category in accordance with AS1554.

Subject to the superintendent’s approval, beam, flange plates, web plates and chord
members may be butt weld in the shop to form any long lengths required provided that
such shop splices are not made at a location on the member which will be highly
stressed. The location and detail of all such butt welds shall be submitted for approval
on the shop drawings.

In the case of compound members, the splices in the individual units shall be staggered
by not less than 60mm.

Where site welding is to be employed, the Contractor shall plan the assembly of
steelwork in sections which will permit a maximum amount of welding to be done on
the ground.

The finished surface and profile of all welding shall be smooth and free from sharp edges
or crevices that would be detrimental to the performance of the structure or to the
protective treatment. All slag and weld splatter shall be thoroughly removed, and the
weld surface shall be replaced, repaired and ground as necessary until satisfactory
surface finish has been achieved.

5.1.11.2 Qualification
The joint preparations, welding consumable and welding procedures shall be qualified.
As deemed necessary by the Company, the Contractor shall submit, in writing, a welding
procedure. Welding shall not commence until such procedure is approved by the
Company.

All shop and field welding shall only performed by welders and supervisors who are
qualified according to Clause 4.11 of AS 1554.

Welder’s certificates shall be made available to the Company on request.

5.1.11.3 Procedure
Weld procedure shall be in accordance with AS 1554 Part 1 and all welding shall
conform to the approved procedure. The operating conditions shall be as per the
equipment manufacturer’s instructions.

The location of all welds shall be shown on the shop drawings, welding symbols shall be
in accordance with AS1101.3.

All fabricated boxed sections shall be completely sealed and exposed welds ground off
flush.

The ends of two butting lengths of a strut or the end of a strut and the contact face of
and adjoining cap plate or base plate shall be in full contact in accordance with AS 1250.

Page 21 of 60
 No flame cutting or welding operations shall be carried out whilst any structural
member is in a state of stress.

Where site welding is to be employed in fabrication, the Contractor shall plan the
assembly of steelwork in section which shall permit a maximum amount of welding to
be complete on the ground. The Contractor shall plan the work in a manner to limit, as
far as possiblle, the amount of overhead welding.

5.1.11.4 Quality
Surface to be welded shall be free from loose mill scale, slag,rust, grease, paint and
other deleterious material. Surface to be welded shall be smooth, uniform and free from
fins, tears and other defects.

All welds on completion shall present an even, smooth and regular finish free from
defects. Weld metal shall be solid throughout with complete fusion beetwen weld
metals and present metal and beetwen successive weld runs throughout the joins.

All webbed connection shall be designed to transmit the full load in the member, except
where full strength welds ares specified, without exceeding the stresses allowed by the
aplicable documents.

No weld which has a length less than four (4) times the normal fillet size of the weld
shall be permitted.

The quality of welds shall conform to Section 6 of AS1554

5.1.11.5 Butt Welds

Unless otherwise shown on the Drawings, all butt welds shall be qualified complete
penetration butt welds, where possible, shall be double V-butt welds, or double U-butt
welds.

All butt-weld of tubular and boxed members shall be backed by suitable mild steel
backing rings or plates, unless approved otherwise.

Surface preparation for all butt welds shall be shown on the shop drawings.

All butt welds designated on the Drawings as “Incomplete Penetration Butt Welds” shall
be qualified incomplete penetration butt welds to AS1554, and shall have full depth
preparation, unless noted otherwise on the Drawings.

Butt welds in section 25mm or more in thickness shall be made with low hydrogen
electrodes.

Over-reinforcement of butt welds and pronounced humps shall be ground off to

produce to smooth profile, or ground flush as specified on the Drawings.

Page 22 of 60
 All site complete penetration butt welds as shown on the Drawings, or at splices
proposed by the contractor and approved by the superintendent, shall be fully tested by
the Contractor.

5.1.11.6 Fillet Welds

Unless otherwise shown on the Drawings, all fillet welds shall be continuous 6mm fillet
welds. No fillet weld smaller than this size will be permitted, unless otherwise shown on
the Drawings.

5.1.11.7 Welding Electrodes and Welding Plant

Unless otherwise shown on the drawings, Grade E48 Electrodes to AS1553 shall be used
for welding of all shop and field welded joints.

In addition to the requirements of AS1554 low hydrogen electrodes shall be kept in their
sealed packets until the time of actual welding.

Immediately after opening a new pack of electrodes they shall be transferred into a
portable drying oven where they shall be kept at a temperature recommended by the
manufacturer. Electrodes which have been exposed to weather and especially to
atmospheric moisture shall be discarded.

Automatic welding procedures and electrode wire shall be of a quality exceeding the
requirements for weld quality specified herein.

Welding plant and equipment shall be in accordance with AS60974.

5.1.11.8 Weld Testing

Where specified on the Design Drawings or elsewhere in the Contract Documents, the
extent of testing and inspection of welds shall include any or all of the following
methods as given by section 7 of AS 1554.

- Radiographically test butt welds

- Ultrasonically inspect and ultrasonically test beam and (including all necessary
preparation) for laminar defects.
- Test critical welds as directed to the extent of 100% by either ultrasonic or
radiographic means.
- Test welds, on plate 38mm thick and over to the extent of 100% and subject all
root passes to magnetic particle detection.

All welds testing shall be in accordance with the requirements of appropriate Australian
Standard and shall be at the Contractor’s expense.

5.1.11.9 Non-Destructive Testing of Welds

The Contractor shall establish a quality control programme for both shop and site
welding. Non-destructive testing shall be performed as necessary to qualify welding
procedures and to ensure that those procedures are maintained througout the works.
Page 23 of 60
 Non-destructive testing shall include visual inspection and ultrasonic and/or
radiographic examination. Test procedures shall be in accordance with AS1554, and
other standards referenced therein.

Result shall be presented in a manner which shall be made available for inspection by
the superintendent.

Should any welds fail to meet the requirements of this specification, the contractor shall
prepare a repair procedure for failed welds which shall be submitted to the
superintendent for approval. If in the opinion of the superintendent, the proposed
repair procedure will induce excessive distortion or residual stresses in the fabricated
members, then it shall be rejected and a replacement member fabricated by the
Contractor.

5.1.12 Gridmesh Flooring

Steel gridmesh flooring shall be used for all walkways, landings, access floors and stair
treads, unlees noted otherwise on the Drawings.
A non-skid nosing angle shall be welded to the leading edge of all stair treads and stair
treads shall be fully welded to stringers with 6mm fillets.
Where grid flooring is to be notched around projections, it shall be neatly done.
Notwithstanding any tolerances nominated by the grid manufacturers, the Contractor
shall select, cut and trim each panel so that, when fixed in position, the maximum
difference in level between adjacent panels shall be not more than 5mm and the
maximum gap between such edges bars shall be not more than 10mm.
Grid flooring shall be clip fastened to the supporting steelwork at the corner of each grid
panel and at not greater than 600mm centers. All clip fasteners shall be as recommended
by the grid manufacturer and to the approval of the superintendent. Site fixing of grid
using site drilled holes and self-tapping screw fasteners shall not be permitted.
All gridmesh flooring and fastenings shall be hot-dip galvanized to the requirements of
this Specification.
Grid flooring shall be Grating Webforge F325 MSG or approved equivalent, as shown on
the drawings.

5.1.13 Platforms, Walkways, Stairways and Ladders

The design, construction and installation of all platforms, walkways, stairways and ladders
shall be in accordance with AS1657. Details shall be as shown on the Drawings, or where
not specifically shown shall be detailed by the Contractor on shop drawings in accordance
with AS1657.

Walkways, platform, stairs and ladders shall be provided to provide access to all places
where maintenance work is necessary. The contractor shall design the walkways and

Page 24 of 60
platforms carefully taking the maintenance work into consideration and submit the layout
drawing for the engineer’s approval.

Stairways, walkways, platforms and floor members shall be designed for superimposed
live load of 2.4kPa, or a point load of 3 kN, whichever is greater. Guard rails shall be
designed to withstand a static load of 500 N applied horizontally, or 890 N applied
vertically at any point along the top rail, whichever is greater.

Walkways shall be provided on both sides of the belt conveyor if the height of carrying
side belt exceeds 2.0 m above ground. The width of both walkways shall be 800mm.
Where the inclination of walkways exceeds 15 degrees, anti-slip devices shall be installed.
The minimum vertical headroom is 2,100mm.

Stair shall be 750mm wide. The inclination angle of stair shall be 45 degrees or less. The
maximum step height shall be 180 to 190 mm. Non slip nosing shall be provided for floor
plates. The maximum height of one flight shall be 2.5 m. if the height is more than 2.5 m,
an intermediate platform 0f 1 m length shall be provided between each flight.

The height of handrail shall be 1,100 mm.

Ladder rungs shall spaced at 300 mm pitch. Where possible, ladders shall be inclined at 15
degree. A safety cage shall be provided for all ladders with height of 2 m or more. The
safety cage for the ladder shall be provided for all ladders with height of the top of the
ladder is 2 m or higher from the ground or floor. Platforms for rest shall be provided if the
height of the ladder exceeds 6,000 mm. The use of ladders shall be minimized and shall
be subject to prior approval by the engineer.

Shop drawings shall indicate the layout of the handrails and the stanchions and the details
of their attachment to the supports, the run of the rails and kickplates, the location of
closure bends between the top and mid rails and of special bends, and the method of
securing kickplates. Special bends are defined as bends having a radius of less than
125mm on the centrerline of the rail.

The top rail shall be continuous throughout its full length and particular attention shall be
paid to the run of the handrail at the top and bottom of each stair flight. Sudden offsets in
the line of the stanchions requiring unnecesarry bends will not be permitted.

Unless otherwise specified and/or shown handrails and kickplates shall be fabricated from
the following minimum sections:

 Top rails Pipe 33.7 mm dia. Top of rail nominally 1020mm above floor level.
 Mid rails Pipe 26.9 mm dia. Top of rail nominally 560mm above floor level.
 Kick plate 100mm x 6mm flat bar for platform or 150x60x6 unequal angle for
walkway. Top of plate not more than 110mm above floor level.
 Stanchions 65x65x6 equal angle at maximum spacing 1500mm centres.

Page 25 of 60
 All joints in handrail shall be qualified partial penetration butt welds. Wels connecting
handrail to stanchions and stanchions to the supporting steelwork shall be 6mm fillets,
unless other details are shown on the Drawings.

Unless otherwise specified and/or shown ladders shall be constructed to the following
minimum requirements, 400mm wide between 50mm x 10mm stringers with 20mm
diameter rungs at centres not less than 250mm nor greater than 300mm. Fixing bracket
shall be provided at the top and bottom of the stringers and at intermediate points not
greater than 3000mm apart, and shall be fixed to the stringers to suit the slope. The
distance from floor or landing level to the rung of the ladder shall be 300mm at the top
and as near 300 mm as is practicable at the bottom. At the top of ladder the stringers
shall in general extend above the landing to handrail height, and return to the landing.

5.1.14 Conveyor covers

The galvanized conveyor cover steel sheets of 2.3 mm thickness. Shall be provided for
whole length of the conveyor except plant conveyor according engineer
recommendation.

5.1.15 Monorails
Monorails shall be provided at the location detailed on the drawings to allow for the
removal of components to ground level. Unless noted otherwise, the centreline of the
monorail shall be located over the centre of gravity of the component so that all lifts are
vertical only.

All connections of the monorail to supporting steelwork shall include bolts, nuts, washers
and lock nuts.

The monorail hoist beam shall be clearly identified by the number and safe working load
painted legibly thereon in accordance with the requirements of the relevant statutory
authority.

5.1.16 Inspection

5.1.16.1 Responsibility
Quality control is the Contractor’s responsibility and the Inspection by the Company is
for verification only. The degree of Inspection by the Company will vary according to the
extent of defective work found.

5.1.16.2 Inspection during fabrication

During fabrication on the Contractor shall permit the Company free access to the
fabrication works at all reasonable times for the purposes of carrying out inspection and
shall afford all necessary facilities for the carrying out of such inspection. Where steel
has been checked and accepted by the Company at the works before being delivered to
the site, such acceptance shall not relieve the Contractor of his responsibility to provide
correct fitting or erection.

Page 26 of 60
5.1.16.3 Inspection prior to transportation
Steel shall not be shipped to site without the Company being given the option to inspect
it.

5.1.16.4 24 hours notice of inspection

The Contractor shall submit a fabrication programme for his work on which the
Company will indicate those items he required to inspect.

Weld inspection will normally be carried out in stages as follow:

a. Material preparation and fit-up

b. Root pass complete
c. Weld complete

The Contractor shall give 24 hours’ noticce to Company of these stages.

5.1.17 Handling, Delivery to Site and Storage

Before, during, and after fabrication, during transit, and while on the site, all structural
steelwork shall be handled and stacked so that it is not damaged, bend or twisted.

At the works and on site, structural steelwork shall be stacked clear of the ground and so
that the collection of water in troughs, pockets and the like, is reduced to a minimum.

At steelwork shall be provided with ready means for lifting and handling. All members
whose individual mass is greater than 1 tonne shall be fitted with suitable lugs for slings.
Small pieces shall be pre-slung at the fabricator’s shop.

Defects or damage shall be repaired and straightened only with the consent of the
superintendent who, at his absolute discretion. Will decide whether the repairs are to be
carried out in the field or the damaged portion returned to the shop.

Where directed by the superintendent, damaged sections shall be replaced.

High strength structural bolts, nuts and washers shall be stored and handled in the works
and in transit to the site in a manner that will prevent damage, contamination, corrosion,
or loss of lubricant.

Should damage, contamination or corrosion occur to the bolts, nuts and washers, the
superintendent may, at his absolute discretion, reject any or all the material affected or
direct that its use may be confined to a particular part of the structure.

5.1.18 Erection
All erection shall be carried out in accordance wiith the requirements of AS4100 and of
this Spesification and the Drawings.

Page 27 of 60
No section of the work shall be erected unless copies of the relevant shop details, and
erection drawings, approved and signed by the Superintendent, are held on the site by
the Contractor.

The Contractor shall have at the site sufficient and adequate plant equipment and
personnel for the proper performance of the work and so as to ensure completion within
the times specified or agreed upon.

The work shall be fully supervised by a capable foreman experienced in this class of work.

The Contractor shall set out lines and levels, and fix and maintain marks for the erection
and checking of positions of steelwork and shall arrange all plant and temporary loads
during erection so as not to overstress any part. Design of temporary erection works shall
be the responsibility of the Contractor.

The Contractor shall be responsible for planning erection procedures including the
provision of all necessary guying, temporary bracing and the like, so as to ensure the
safety of the structure under all conditions of wind and erection loads occuring during the
construction period.

At all times, the number of field erection bolts or erection welds used shall be sufficient to
ensure that the structure is adequately and accurately held together and in position.

If the stability of the structure during construction is dependent upon temporary bracing
or propping, the temporary bracing shall remain in position until the structure has been
completed. The Contractor shall be responsible for ascertaining any such requirements
and notifying the Superintendent before erection commences.

Upon completion of the work, all temporary bracing and its connections shall be
removed, holes plugged and the steelwork, including the protective coating specified, and
made good.

All steelwork shall be erected in such a manner and lifted from such points that members
shall not be overstressed or distorted during lifting operations.

During erection, the use of steel sledge hammers in driving or hammering beams,
columns, or other steelwork will not be allowed, except with the approval of the
Superintendent. Wooden mauls shall be used whenever practicable.

Care shall also be exercised to prevent the material from falling or from being in any way
subjected to heavy shock.All portions of the framework shall be true and plumb within
the tolerances specified in AS4100.

Levelling and plumbing shall begin as soon as practicable after commencement of

erection and shall proceed at the same rate as the erection of new steelwork. The amount
of steelwork erected without levelling and plumbing shall not be so great that proper
adjustment cannot be achieved without damage to or distortion of members.

Page 28 of 60
 The Contractor shall correct any minor misfits by moderate use of drift pins, and
moderate amounts of reaming, chipping or cutting. Any major errors by the fabricator
which prevent the proper assembly of the steelwork shall be promptly reported to the
Superintendent

Should the Contractor require packs or shims in order to meet the erection tolerances
specified, they shall be supplied, fabricated and delivered to site by the contractor. All
shims shll be fabricated from grade 316 stainless steel.

5.1.19 Grouting of Base Plates

The grout shall be a non-shrink, ready-to-use, fluid precision grout material, premixed and
packaged at the manufactirer’s factory and delivered to job site requiring only the
addition of water, and the forming, placing and curing of his grout material.

The grout shall comply with the relevant clauses of AS3600 and AS2072, AS1478 and AS
MP20.3.The Contractor shall obtain the Superintendent’s approval to the proposed grout
types and curing compound prior to grouting operations being carried out.

The grout shall be mixed and placed strictly in accordance with the Manufacturer’s
written instructions.All exposed areas shall be cured with curing and sealing component
complying with ASTM C309 in accordance with the Manufacturer’s recommendations.

No grout shall be placed if the temperature of either the grout, base plate, etc. or
concrete base is above 30 degrees celsius or below 5 degrees celsius.Precautions shall be
taken to avoid the formation of air pockets and the edges shall be neatly bevelled off on
completion.

When the grout has cured sufficiently to be able to carry the load of the structure without
any detrimental effects, any steel wedges, packs or levelling devices use to hold the
column in position shall be removed and the resultant cavities in the grout made good.
Such items may only be left permanently in position with the approval of the
superintendent.

5.1.20 Surface Coatings

5.1.20.1 Surface Preparation

Surface preparation shall be carried out in accordance with the Technical Specification
For surface protection.

a. Steelwork to be Concrete Encased

Steelwork which is to be solidly encased in concrete shall comply with clauses 5.1.19.4
and 5.1.20.2 and shall be kept free of oil, grease, dirt and other deleterious matter until
so encased.Only approved solvents shall be used for the the removal of oil, grease and
the like.
Page 29 of 60
 Steelwork which is to be built in using brick, block , stone or timber shall comply with
clause 5.1.19.4 and 5.1.20.2.

b. Steelwork to be Hot Dip Galvanised

The steelwork shall be cleaned by a suitable preliminary method prior to subsequent

pickling to produce a clean metallic surface suitable for galvanising. Defects following
pickling (including embrittlement) shall be rectified.

c. Steelwork to be Spray Metal Coated

The surface preparation shall be by pickling or abrasive blast cleaning to AS 1627 and
conform to the contractor’s requirement.

d. Steelwork to be Painted

The steelwork shall be cleaned by abrasive blast to a standard of finish equal or better
than Class Sa 2.5 described in AS 1627. Any substance used for grit blasting containing
free silicon shall not be used as an abrasive in blast cleaning operations.

The initial paint coating shall be applied to the freshly cleaned surface before any
tarnishing develops. If tarnishing appears on the surface the steelwork shall be cleaned
again to the appropriate standards.

5.1.20.2 Protective Coating

a. Concrete Encasement

The minimum thickness of concrete encasing shall be 50mm.The casing shall be

reinforced with wire complying with AS 1303. The diameter of the wire shall be at least
5mm. Alternatively, reinforcement shall be structural grade bars complying with AS
1302. The diameter of the bars shall be at least 6mm. In either case the reinforcement
shall be in the form of stirrups or binding at not more that 150mm pitch and so arranged
as to pass through the centre of the covering to the flanges and supported by and
attached to at least four longitudinal spacing bars.

b. Painting

Painting shall be carried out in accordance with the Technical Specification for surface
protection.

Page 30 of 60
5.2 Concrete Work
5.2.1 Extent of Work
The work comprised under this section includes for concrete the supply all materials,
manufacture of concrete, forming, mixing, placing and finishing of all concrete work,
complete, as shown on the drawings, and as necessary for the completion of the Works.
The extent of work shall include, but not be limited to :

 Foundations for at grade and elevated conveyor

 Foundations for transfer towers
 Concrete slab
 Foundation for Surge bin
 Foundation for CBU
 Foundation for Shiploader facility
 Jetty

5.2.2 General Requirements

All concrete work shall conform to the requirements of AS3000 except where varied by
this specification.

The contractor shall keep a copy of each of AS 1012, AS 1379, AS3600 and AS3610 on the
job at all times.

5.2.3 Supervision
The Contractor shall employ on the site an experienced foreman concretor, whose sole
responsibility shall be the supervision of the concrete work.

The foreman shall organise and direct the placing, compacting and finising of the
concrete, during which operation he shall be in continuous attendance.

Before construction commences the Superintendent will nominate to the Contractor

those elements that the Superintendent considers to be critical and no concrete shall be
placed in those elements except in the presence of the Superintendent.

The Contractor shall keep on the site and have available for inspection by the
Superintendent at any time a log book in which is recorded the following information
regarding each placement of concrete:

a. Date of placing concrete

b. Portion of the work constructed
c. Specified Grade of Concrete and source
d. Slump measurements taken
e. Volume of concrete placed
f. Test specimens made

Page 31 of 60
5.2.4 Inspection
The formwork and reinforcements for each concrete placement will be inspected and
approved by the Superintendent before any concrete is placed in the section of the work.

All formwork, reinforcement, reinforcement support, cores, holding down bolts, conduits
and the like shall be in position and the Superintendent notified at least one clear working
day before concrete is placed iin any section of the work.

Prior to the Superintendent’s inspection, the Contractor’s sectional foreman shall carry
out detailed check of the work, making any corrections found necessary for the work to
be in full accordance with the working drawings and the requirements of this
Specification.

The foreman or supervisor shall be present and assist the Superintendent in his
inspection.

When the work is correct and is clean the Superintendent will give written approval for
the concrete to be placed. The work shall be maintained in a clean, satisfactory condition
until concreting is completed.

5.2.5 Materials for Concrete

5.2.5.1 Cement
Unless noted otherwise on the drawings all cement used shall be Type “A” Portland
Cement of approved brand, and shall comply with the requirements of AS 3972.

Cement shall not be more than six months old when used in the work and any cement
that has become lumpy or partially set prior to mixing will be condemned and shall be
removed from the site immediately.

Blended cements shall only be used with the prior written consent of the
superintendent and subject to any conditions for use which he may impose.

5.2.5.2 Aggregates
All fine and coarse aggregates used in concrete shall be normal weight (not lightweight)
non-slag aggregates conforming to AS2758-1 and to requirements specified here in.

Special requirements under AS 2758-1 shall be:

a) Water absorption (Clause 8.3) shall not exceed 5%

b) Grading requirements (Clause 9.1) shall be based on “submitted grading” which
shall be supplied to the Superintendent
c) Durability requirements (Clause 10) for all aggregates shall be as for severe
exposure classification concrete. Coarse aggregate durability shall be in
accordance with Clause 10.2.1
d) The materials listed in Clause 13 shall be unacceptable
e) Fine aggregate shall comply with Clause 14.1 for organic impurities
Page 32 of 60
 f) All of the aggregates shall comply in every respect with the requirements of
Clause 14.3 for alkali-reactive materials

The variation in moisture content of each aggregate shall be closely monitored and
adjustments made in the batching to ensure that the aggred mix proportions for each
grade of concrete are maintained.

At least thirty (30) days prior to the placing of any concrete, the contractor shall submit
to the Superintendent for approval test results demonstrating that the supplied
aggregate conforms to the above requirements.

Except where noted otherwise on the drawings, or in this specification the maximum
aggregate size for all concrete shall be 20mm.

5.2.5.3 Water
Water for concrete shall be:

a) Potable; or
b) Clean and free from oil and injurious amounts of alkalis, salts, organic materials
or other substances that may be deleterious to concrete or reinforcement

Attention is drawn to the requirements of “Sampling and Testing” and, if the Contractor
proposes using water which is non-potable, samples of the water shall be tested by the
Contractor and shall not be used until approved in writting by the superintendent.

5.2.5.4 Admixtures
No admixtures or air entraining agents or admixtures to provide line lubrication where
concrete pumping is employed, shall be used, unless approved in writting by the
Superintendent.

Unless specified otherwise, or shown on the drawings, fly ash may be incorporated in
the concrete. The fly ash shall comply with AS3582.1 and the amount incorporated shall
not exceed 25% of the cement/fly ash blend. Fly ash be blended in the mixing plant.
Concrete mixes containing fly ash shall be identified in the batching plant records and on
the delivery docket.

Only 50% of the mass of the fly ash shall be considered in determining the “effective”
cement content of the mix.

Should any other substance, apart from cement, fly ash, aggregate, and water as
specified, be added to be concrete without the written approval of the Superintendent,
the Superintendent may at his absolute discretion, refuse to authorise payment for any
such concrete and may require the removal of any concrete in which the said substance
has been used.

Page 33 of 60
5.2.5.5 Steel Reinforcement
All steel reinforcement and the placing and fixing of all steel reinforcement shall comply
with the requirements of AS3600 and AS4671.

The minimum yield strength of the steel reinforcement is as follow:

 Plain reinforcement bar : Fy = 2400 Kg/cm2

 Deformed reinforcement bar: Fy = 4000 Kg/cm2

The Contractor shall, upon request by the superintendent, supply copies of test
certificates representing routine tests for yield and ultimate strengths, elongation and
cold bend performances carried out by the steel Supplier confirming that the steel
supplied conforms to the specified requirements.

All reinforcement shall be furnished in the full lengths shown and laps and splice shall be
made only in the positions and to the dimensions shown or otherwise approved by the
Superintendent. Welded joints other than those specifically detailed, shall not be made
without the approval of the Superintendent. Any such approval will only be given
subject to the provisions of AS1554 – Part III being strictly adhered to.

Proprietary types of mechanical/welded bar splices will only be permitted where

specified and/or shown.

Wihtout the approval of the Superintendent, reinforcement shall not be bent, except as
shown in the bending lists.

Notwithstanding the provisions of AS3600, under no circumstances shall cold worked

bars be straightened after bending. Where this has been done for access or clearance
purposes, the Superintendent may require the bars to be removed and replaced by
demolishing the surrounding concrete if necessary. The cost of such remedial work shall
be borne by the Contractor.

Notwithstanding the provisions of AS3600, the heating of reinforcement will not be

permitted. All bends and hooks shall be cold bend and, where not dimensioned, cogs,
hooks and bends shall be bent in accordance with the requirements of AS3600.

Hard drawn steel wire fabric shall be delivered to the site in flat sheets, except that the
fabric for slabs supported permanently on the ground may be supplied in rolls.

Steel reinforcement shall not be supported on pieces of wood, stone or aggregate. Steel
shall likewise not be supported on metal supports (other than stainless steel) which
extend to the surface of the concrete. Where concrete strips or blocks are used to
support slab reinforcement the concrete shall be of the same strength and density as
the concrete itself, and shall be thoroughly compacted.

Page 34 of 60
 The clear cover to the reinforcement shall be as shown or, where not shown, shall be in
accordance with the requirements of Australian Standard 3600 for Exposure Condition
C.

The Contractor shall be responsible for the preparation of steel bending lists and the
ordering of all reinforcing steel.

The Contractor shall shall prepare & supply three (3) complete sets of steel bending lists
and drawings show his bar notation to the superintendent prior to commencement of
reinforcement bending. The Contractor shall remain completely responsible for the
provision of all reinforcement in accordance with the drawings and appropriate
Standards.

5.2.5.6 Site Mixing

All concrete shall be mixed on site.

The Contractor shall submit details of the mixing plant, batching plant and transit mixers
to the Superintendent for approval.

All concrete mixing shall be done in mechanically driven rotating batch mixers of
approved type conforming to AS 1379.

The Contractor shall submit to Superintendent, details of all the materials and the
designs of the mixes he proposes to use in work.

Immediately the site mixing plant is operational the Contractor shall conduct trial
batching and mixing and testing as required to establish that the metods and materials
he proposes to use will produce satisfactory concrete meeting all the requiremnts of the
specification, in the required quantities and at the required rate.

The Superintendent shall be given at least three days notice of the Contractors’s
intention to conduct trial mixing and testing and no such work shall be carried out
unless the Superintendent or his representative is present.

Sampling and testing of all trial mixes and production concrete for use in the works shall
be strictly in accordance with AS 3600, and as outlined in Clause 4.3.24 of this
specification.

No permanent or load bearing concrete shall be produced from a site mix plant until the
results of these trial mixes are available and have been accepted and the mixes
authorised by the Superintendent. If the trial mixes fail to meet the specified
requirements, they shall be adjusted and tests of the trial mixes shall be re-run.

After the mix design has been so established, and approved by the Superintendent, it
shall not be changed throughout the duration of the Contract without the permission of
the Superintendent.

Page 35 of 60
 All concrete shall be delivered in trucks of the revolving drum type conforming to
Australian Standard 1379 and all concrete shall be completey discharged, placed and
compacted in its final position within 60 mniutes of the introduction of the cement to
either the water, the aggregates or the mixer.

In no circumstances shall water or any other substance be added to the concrete, after
the initial introduction of the water to the cement, without the approval of the
Superintendent.

Before commencing a run of concrete, hardened concrete and foreign material shall be
removed from the inner surfaces of the mixing and conveying equipment.

The concrete shall be mixed in the quantities required for immediate use and shall be
placed in position as rapidly as possible.

Mixing by hand will not be permitted except in an emergency and then only with the
approval of, and to the satisfaction of the Superintendent. Hand mixes batches shall not
exceed 0.2m3 in volume and the mixing shall be done on a clean water-tight platform.

5.2.5.7 Measurement of Materials

All concrete materials, including water and cement shall be accurately measured.

Water shall be supplied directly from an approved water measuring device with a visible
indicator showing the quantity of water measured and with the controls so arranged
that only measured quantities of water shall flow into the mixer.

Fine and coarse aggregates shall be measured by mass. Correction for bulking of fine
aggregate owing to contained moisture shall be made to ensure that the requisite
amount of dry fine aggregate is used. The correction shall be adjusted as often as the
Superintendent may consider necessary to allow for variations in the moisture content
of the fine aggregate.

Scales on weigh batching plants and volume batching equipment for dispensing water
shall be calibrated yearly or when moved. The Superintendent shall witness this
calibration.

Batching procedures shall be such as to enable the necessary allowance to be made for
variations in the moisture of the aggregates.

5.2.6 Supply of Concrete

It shall be the responsibility of the Contractor to supply, set up and commission a
concrete batching plant which shall supply all concrete required for the project.

The batching plant and transit trucks must have the capacity to batch and deliver a
minimum of 15m3 per hour.

Page 36 of 60
5.2.7 Quality of Concrete
The specification of the concrete shall be by required properties as defined in AS 3600
with the required properties for each element of the work being as shown on the
Drawing. Unless otherwise shown on the Drawing all concrete shall be special class
complying with the following specification and AS3600:

 Characteristic compressive strength of 32 Mpa

 Concrete shall have a slump of 75mm
 Maximum aggregate size shall be 20mm
 Minimum effective cement content shall be 340Kg of cement per cubic metre of
concrete
 Concrete shringkage shall not be more than 0.07% at 56 days

The concrete shall be designeted S32. Standard slump testing apparatus shall be provided
by the Contractor with slump tests performed and recorded for every batch.

The slump shall be within the limits specified in AS 3600 for the slumps shown on the
Drawings.

For all othe concrete the maximum aggregate size shall be 20mm.

The chloride ion content of the concrete as placed shall not exceed 0.2% by mass of
portland cement content of the concrete.

All concrete shall be completely discharged placed and compacted in its final position
within 60 minutes of the introduction of cement to either the water, the aggregates or
the mixer.

In no circumstances shall water or any other substance be added to the concrete by the
contractor without specific approval of the Superintendent.

5.2.8 Stabilised Sand

If required, stabilised sand shall comprised and intimite mixture one part cement to
eighteen parts by volume of clean aggregate sand or, where pumping is required, clean
pit sand. A quantity of water sufficient to facilitate placing and compaction shall be used.

5.2.9 Preparation of Surface before Placing of Blinding

Horizontal surface in tight soil comprising fine grained relatively non-porous materials
such as clay and loam shall be sprayed with water if necessary to ensure that the material
is moistened to a depth of 100mm.

Horizontal surfaces of sand shall be soaked with water and compacted by vibrating plate
compactor to not less than 95% of the maximum dry density as determined by AS1289
Test E5.1 to a depth of at least 250mm immediately prior to the placement of concrete
blinding layer. The sand surface shall not be permitted to dry out nor shall it be rewetted
prior to placement of the concrete blinding layer.
Page 37 of 60
 All rubish and debris or loose material which might contaminate the concrete shall be
removed before any concrete is placed.

5.2.10 Concrete Blinding Layer

A concrete blinding layer 50mm thick, or as shown on the drawings, comprising grade 10
concrete shall be placed below the underside of all footings and slabs placed on the
ground. Its purpose is to protect the fooundation material and to provide a clean, firm
and level surface on which to support the reinforcement and formwork.

This concrete shall be placed as soon as possible after the excavation has been complete
and the foundation material prepared as above and approved. The surface of concrete
shall be screeded to an even finish level with the underside of the structural concrete to
be placed over.

5.2.11 Formwork and Falsework

It is the Contractor’s responsibility to design and construct formwork and falsework in
accordance with AS3610. Attention is drawn to Appendix C of the code which defines the
information to be supplied by the Superintendent either on the Drawings or in the
Specification.

The standard of surface finish tobe achieved shall be in accordance with AS3610, and as
specified elsewhere herein. Colour uniformity shall be Class C where Class 2 formwork is
specified.

The Contractor shall check the formwork, prior to placing the concrete. All dimensions,
particularly those affecting the construction of subsequent portion of the work, shall be
carefully checked.

Notwithstanding any inspection or approval by the Superintendent, the responsibility for

the structural sufficiency of the whole of the formwork and falsework shall remain
entirely with the Contractor.

Forms shall be so designed and constructed that they may be removed without injuring
the concrete surfaces and without excessive jarring or hammering.

Forms shall be erected true to line with all joints either vertical or horizontal, and shall be
rigidly braced and adequately supported by falsework, props, wedges, or other means so
as to carry the weight of the concrete to be placed without sagging or moving from true
line and position.

Should any formwork be displaced during concreting or within the period specified for the
retention of formwork, the concrete shall be removed between such limits as the
Superintendent may determin, construction joints shall be formed and the section of
work reconstructed, after the formwork has been strengthened and adjusted.

Notwithstanding the provisions of AS 3610 the deviation of any point on the surface of a
concrete element from its correct position in space shall not exceed 10mm.
Page 38 of 60
 The relative deviation of any two point on the surface of concrete element from their
correct positions in space shall not exceed 1/500 of the dimension between them except
that in the case of cross-sectional dimensions of structural members such as comuns ,
beams, slabs and walls, the tolerance shall be minus 0 plus 6mm. Nevertheless, this last
concession shall not apply to the measurement of flatness of formed surfaces.

Except in the case of class 5 formwork, all formwork corners where the enclosed angle is
less than 120 deg. Shall be filleted, the bevel in each case having a width as shown or, if
not shown, of 20mm on each side with equal angles in all cases.

The following classes of formwork shall be used:

 Concealed from view Class 4

 All other surfaces Class 2

All in accordance with AS3610 except that the surfaces of adjoining panels at joints shall
be aligned to within:
 1.5mm for Class 2
 3mm for Class 4

Alumunium alloy sheeting shall not be used as formwork.

The number of re-uses and the conditions of faces and edges of forms shall be consistent
with the formwork surface class specified. Forms shall not be disturbed until the concrete
in contract with them has hardened sufficiently to withstand such action without damage.

Forms and falsework beneath the soffit of self-supporting concrete elements shall not be
removed until the elements can support themselves and any superimposed loads safely
and without excessive deflection.

Removal of bottom forms between bearers or props prior to the removal of supports may
be permitted by the superintendent, provided the formwork has been designed to allow
such removal without disturbance of the supports.

The Contractor shall submit, to the Superintendent, details and calculation of his
proposed construction cyclle including propping procedure, construction loads and details
of estimated rate of gain of strength of the concrete. The Superintendent will then check
that no system will carry in excess of its capacity and will advises the Contractor
accordingly.

No permanent loading shall be imposed on the concrete member while it is still

supported by formwork.

5.2.12 Formwork Ties

Formwork ties shall be used consistent with the class of surface finish specified for the
members as a whole and with the approval of the Superintendent.

Page 39 of 60
 Embedded ties for holding forms shall remain embedded. Clear cover to embedded ties
shall be not less than the cover to nearby reinforcing bars. The ties shall be constructed so
that removal of the ends or end fasteners can be accomplished without causing spalling at
the faces of the concrete. Form ties shall be kept clear of the steel reinforcement and in
no circumstences shall steel reinforcement be used to support the formwork.

Recesses resulting from the removal of form ties, shall be thorougly cleaned and
saturated with water then filled with mortar in the proportion of one part of cement to 3
parts of sand, well rodded, and floated flush. If in the opinion of the Superintendent the
finished surface is not satisfactory, further treatment using the mortar specified above
and rubbing down with a medium coarse carborundum stone shall be carried out untuil a
surface is produced which is clean, smooth and consistent with the class of surface finish
specified for the member as a whole.

Tie wire passing through the concrete will not be permitted.

Cone spacers shall be removed within two (2) working days of form stripping. Recesses
formed by cone spacers shhall be cleaned on removal of spacers and filled with mortar in
the proportion of one (1) part of cement to three (3) parts of the sand used in the
concrete in which the recess occurs. Cone spacers shall not be welded to the
reinforcement or fixed in any way which will impede their removal from the concrete. No
recesses shall be filled until they have been inspected and submitted for approval by the
Superintendent. Sample patching shall be carried out by he Contractor and approved by
the Superintendent before proceeding.

5.2.13 Preparation of Formwork Surfaces before Placing of Concrete

Before commencing to place concrete in any section of the work, the formwork shall be
checked for accuracy and thigtness, and all joints and holes shall be effectively sealed.

All form linings shall be treated prior to placing of concrete with a suitable release agent
which shall be applied before the forms are erected or any reinforcement is placed.

Sufficient tests shall be undertaken prior to use to ensure that no reaction which will
adversely affect the concrete surface will occur between any form release agents, surface
coatings or curing compounds.

All rubbish shall be removed from the space to be occupied by the concrete and the work
blown clean before and again after the Superintendent’s inspection.

Immediately before the concrete is placed, the forms and other surfaces to come in
contact with the concrete whall be sprayed with water and all ponded excess water than
removed.

5.2.14 Placing of Concrete

All chutes, skips, hoppers and the like shall be thoroughly cleaned and flushed with water
before each concreting operation.

Page 40 of 60
 Notwithstanding the provisions of AS1379 all concrete shall be completely dishcarged,
placed and compacted in its final position within one hour of the introduction of the
cement to either the aggregates or the mixer.

The Contractor shall monitor concrete placement temperatures and as required ensure
adequate measures are in place to limit the concrete temperature at placement to 32
degrees Celsius. The measures employed shall be submitted to the Superintendent for
approval.

Concrete shall be compacted by means of approved high frequency mechanical vibrators

of the immersion type with a minimum frequnecy of 120 Hz and with sufficient enery
output to ensure complete compaction of all parts of the concrete sections.

Vibrators shall be used in sufficient numbers to keep pace with the rate of placing of the
concrete and shall be handled by trained operators to ensure that the pattern of inserting
the vibartors produces even and regular compaction. Care shall be taken to avoid over-
vibration and the method of handling the vibrators shall at all timed be to the approval of
the Superintendent. Vibrators shall not be permitted to rest against formwork or
reinforcing steel and shall not be used to move concrete laterally. Tamping, spading and
slicing shall be used in those locations where it is not possible to use vibrators effectively.

The Contractor shall keep on the site sufficient “stand-b” vibrators in correct working
order to ensure continuity of work in the event of plant failures.

The full thickness of all slabs, beams, footings and pile caps shall be conreted in the one
operation.

If a cessation of work becomes unavoidable, a construction joins shall be formed as

specified elsewhere herein,, at the point of shopping.

When work is resumed the treatment of the concrete at the cold joints shall be as
specified under “Contruction joints”

Unless approved by the Superintendent, in writting, no concrete shall be placed under

water and permission to do so will only be given in the most exceptional circumstances.

All concrete shall be placed in daylight and the placing of concrete in any portion of the
rok shall not be started without the approval of the Superintendent and unless it can be
completed in daylight. Permission for night work will not be given unless adequate system
of lighting is provided and approved.

5.2.15 Pumping
Approval to use concrete pumps to place concrete may be given by the superintendent
subject to the Contractor submitting full details of the type and capacity of the pumps,
pipe work and procedures to be adopted, and satisfactory evidence tthat any
modifications to the concrete proportions and consistency to suit pumping procedures
shall comply with the provisions and intent of this Specification.
Page 41 of 60
 The pump shall have a variable speed control and shall be capable of pumping concrete
containing 20mm aggregate through delivery lines not less than 75mm diameter.

Delivery lines shall be of an approved metallic type. Under no circumstances shall

aluminium alloy pipes or fittings be used nor shall concrete be permitted to come in
contact with alumunium during its manufacture, transport or placing.

Where delivery lines shall be exposed to hot sun they shall be protected by covering with
bags, wet hessian or other approved means.

Direct efficient communication shall be maintained at all times between the pump
operator and the concrete placing crew.

During delays in delivery of concrete to the pump, concrete in the lines shall be pumped
at approximately 10 minute intervals (5 minutes in hot weather) to ensure that the
concrete is “live”. For piston type pumps at least two strokes of the piston shall be made
at each pumping interval.

In the event of delay or breakdown in the equipment not exceeding 20 minutes during
which time concrete cannot be placed the concrete already in place shall have the “wet
edges” maintained in an approved manner.

If the delay exceeds twenty minutes an emergency construction joint shall be formed
where directed, the concrete completed to it and all concrete in the pipeline discarded.

Concrete placement shall not be recommended if the Superintendent considers that

initial setting of the concrete already placed has begun.

Should the temperature exceed 30 degrees C, the receiving hopper and lines shall be
cleaned out and the concrete contained therein discarded. Where the temperature lies
below 30 degrees C, the using or discarding of the concrete shall be determined at the
sole discretion of the Superintendent.

In any case, if initial setting of the concrete has begun in the hopper or discharge lines,
the concrete shall be discarded.

5.2.16 Finish of Concrete Surfaces

All formed concrete surfaces which are to remain exposed shall finish clean and even
when the forms are stripped.

The surface finish shall meet the requirements for the formwork category specified
elesewhere herein or shown, as laid down in Australian Standard 3610.

Should any surface fail to meet the specified requirements as determined by the
superintendent, the Contractor shall grind, or otherwise treat the surface to achieve the
required standard or finish as directed by the Superintendent. Rendering will not be
acceptable.

Page 42 of 60
 Immediately after the formwork has been removed and while the concrete has still not
fully hardened, all inequalities shall be rubbed or chipped off.

Any places not entirely filled with mortar shall be pointed up or cut out square and
replaced with new concrete as directed by the Superintendent.

If, after stripping of the formwork, any areas of segregation or honeycombing are found,
these shall be cut out and made good as directed by the Superintendent.

Repair procedures will depend on the extent of defective areas and may require the use
of wet to dry epoxies, epoxy mortars and non-shrink grout.

No concrete shall be covered up until it has been inspected and approved by the
Superintendent.

The upper surface of slabs and concrete screeded to line and level shall be floated and
trowelled to a smooth even finish so that it may be easily sewpt, but without gloss that
will cause slippery walking conditions. The surface shall be finished with a light room to
the reuirements of the Superintendent.

All joints shall be marked and formed to a straight line with a bronze jointing tool, edges
that do not fnish against steelwork shall be rounded and formed with a similar edging
tool.

No traffic shall pass over fresh concrete unless it is duly protected by planks or other
method approved by the Superintendent.

All screeding, floating, trowelling, jointing and edging of surfaces shall be done either by
tradesman plasterers or by specialist workmen thoroughly experienced in such work. It
shall be first class work throughout.

During trowelling the surface shall not be dusted with cement, or a mixture of sand and
cement, to absorb moistyre or to facilitate trowelling.

5.2.17 Tolerances for Floor Surfaces

The finished surface of floors shall not debiate by more than 10mm from the specified
design level at any point.

The finished surface of floors shall not deviate by more than 6mm from the testing edge
of an approved straight edge of 3m length laid in any direction.

Where directed by the Superintendent, areas of floor surfaces which do not comply with
the above shall be corrected by grinding or other means approved by the Superintendent.

5.2.18 Construction Joints

A construction joint is the junction between two successive concreting operations in an
element intended to act monolithically.

Page 43 of 60
 Construction joints. If indicated oh the Drawings shall be formed and constructed to the
details and in the locations shown and they shall not be waried without the approval of
the Superintendent.

Additional construction joints may be made to details and in locations approved by the
Superintendent. Such joints shall be planned as far as possible and their number shall be
kept a minimum.

Whenever the work of placing concrete is delayed so that the initial set, as determined by
the Superintendent, has taken place, the point of stopping shall be deemed a construction
joint and formed accordingly.

Where such a point of stopping occurs at a location considered unsuitable by the

Superintendent, the Contractor shall remove such concrete already placed as will enable a
satisfactory construction joint to be formed where directed by the Superintendent.

All construction joints shall be truly vertical or horizontal. Inclined or feathered joints will
not be permitted.

When placing concrete above a horizontal construction joint appropriate measure shall
be taken to ensure that aggregate segregation does not produce honey-combing at the
joint.

Where shown and/or directed by the Superintendent, construction joints shall be sealed
with an approved joint sealant as specified elsewhere herein.

5.2.19 Curing of Concrete

The Contractor shall ensure that all concrete is properly and adequately cured. The curing
methods shall be submitted for approval by the Superintendent before any concrete is
placed and the Contractor shall modify or change the curing procedures as directed by
the Superintendent at any time during the work of the Contract if the Superintendent is
not satisfied that the concrete is being properly cured.

Initial curing of exposed concrete surfaces shall be commenced as soon as the surface of
the concrete has hardened sufficiently to prevent damage and in any case the same day
that the concrete is mixed and placed and shall continue for not less than twelve hours.
The concrete surface shall be kept continuously moits, preferably by ponding but, where
this method is considered imppracticable, by the use of an absorbent cover kept
continuouly wet.

Final curing shall commence immediately following the initial curing period and shall
continue for not less than seven (7) days or such longer period as the Superintendent may
direct. During this period, the curing shall be carried out either by continuing the method
used during the initial curing period or by covering the concrete with waterproff sheeting
which shall be maintained in close contact with the surface of the concrete.

Page 44 of 60
 The edges of the sheeting shall be taped or shall overlap by at least 200mm and the whole
shall be held securely in position. Any damage to, or displacement of, the sheeting during
construction shall be made good immediately and, should the concrete surface show
signs of drying out during the final curing period, the sheeting shall be temporarily
removed, the surface of the concrete wetted and the sheeting replaced as before.

Steel forms exposed to direct sunlight and all wood forms in contact with the concrete
during the final curing shall be kept wet. If forms are removed during the curing period,
one of the previously described curing methods shall be employed and continued for the
remainder of the period.

Alternatively, liquid membrane curing compounds of the wax emulsion or chlorinated

rubber tpe conforming to the requirements of ASTM – C309 may be used during the final
curing period on walls and other surfaces provided that the Contractor establishes to the
satisfaction of the Superintendent that they can be applied and maintained effectively
and that they are compatible with any subsequent surface finish. The proposed type and
brand curing compound shall be submitted, in writing to the Superintendent before use.
The application rate shall be in accordance with the manufacturer’s instructions, but shall
be not less than one litre to 5m2.

Liquid membrane curing compounds shall not be used on floors or paving unless the
surface is protected against scuffing or damage by means approved by the
Superintendent.

5.2.20 Sampling and Testing

All concrete supplied for the contract shall be subject to project control testing in
accordance with AS3600.

Requests to vary the criteria for acceptance of concrete may be considered provided
details of such variation and confirmation by test results are submitted in writing to the
Superintendent at least seven (7) days before any concreting operations are to
commence.

The manufacture and testing of all concrete test cylinders shall be carried out by the
Contractor. The concrete compression machine shall be calibrated on a yearly basis, or
whenever the machine is moved. The calobration shall be carried out by a registered
laboratory approved by the Superintendent. The conformance tsting of cylinders shall be
witnessed by the Superintendent.

At least three (3) cylinders shall be prepared for each sample and one of those three
cylinders shall be tested when the concrete is seven (7) days old.

The Contractor will keep on the site a log book in which he will record the following
information

a) Date and time of taking the sample

b) Number of delivery docket and number of the transport vehicle
Page 45 of 60
 c) Location of sampling
d) Method of identifying the test cylinders taken
e) Location of batch of concrete after its placement
f) Slump of sample
g) Date of test
h) Test results (strength and density)

This log book shall be available for inspection by the Superintendent.

Details of the proposed testing laboratory and arrangements for testing as required by
this clause shall be submitted to the Superintendent for his approval.

5.2.21 Rejection of Concrete

Where concrete already placed is classed as defective and liable to rejection, the criteria
for rejection shall be as set out in AS3600.

5.2.22 Removal of Formwork

The responsibility for the safe removal of any part of the formwork or falseworm shall rest
entirely with the Contractor.

Removal of forms and falsework shall be in accordance with AS3600 unless stated
otherwise in this Clause.

Forms shall not be disturbed until the concrete in contact with them has hardened
sufficiently to withstand such action without damage.

Paricular attention shall be paid to prevent damage to the concrete surfaces if form bolts
or ties are bent during removal operations.

Forms to horizontal surfaces may be removed before supporting shores are removed
provided that the formwork system is designed to facilitate the operation without
disturbing shores.

Where forms to horizontal surfaces are removed prior to the removal of supporting
shores, the minimum stripping time for forms shall be governed by the time required for
concrete to gain sufficient strength to support its own dead load and construction loads
between shore support points but in no case shall be less than five (5) days.

Forms to vertical surfaces shall not be removed until the recommended stripping times
tabulated in AS3600 have elapsed.

Should any formwork be displaced during concreting or within the periods specified for
the retention of the formwork, the concrete shall be removed between such limits as the
Superintendent may determine, constrcution joints shall be formed and the section of
work shall be reconstructed after the formwork has been strengthened and adjusted.

Page 46 of 60
 Concrete work which does not comply with the tolerances specified or has other defects
due to the inadequacy of the formwork shall be removed and replaced or the defects
shall be remedied as directed by the Superintendent.

Neither walls nor any permanent loading shall be erected on any part of the strcture
while it is still supported by formwork.

Immediately after the formwork has been removed, all inequalities shall be rubbed or
chipped off.

Any places not entirely filled with mortar shall be pointed up or cuy out square and
replaced with new concrete as directed by the Superintendent.

If, after stripping of the formwork, any minor areas of segregation or honeycombing are
found, these shall be cut out and made good as directed by the Superintendent.

All repairs shall blend with the adjacent concrete surfaces in colour and in texture.

No concrete shall be covered up until it has been inspected and approved byy the
Superintendent.

5.2.23 Core Holes and Building-In

The Contractor shall supply where required and build into the concrete all holding down
bolts, core holes, pipes, pockets and inserts, and all collars, sleeves, or thimbles required
for piping and wiring anchors, pockets or inserts for supporting strips, hanging wires, steel
frames and cable supports, unistrut fitting and other metal fittings, and all other items
required or shown.

The Contractor shall notify all Nominated Subcontractors and other Contractors whose
work is in any way connected with or influenced by the concrete work and give them
reasoonable time to complete all portions of their work that must be placed before
concrete is deposited in the forms.

The Contractor shall ensure that all items to be cast into the concrete are firmly secured
in the forms so that they will not move during placing of the concrete.

All items to be cast into concrete shall be free of loost rust, mill scale, dirt, paint, grease,
or any other deleterious substances.

All formwork for all core holes to be formed in the concrete for holding down bolts shall
be painted with “Redalon” or a similar approved compound.

On removing the formwork the surface of all core holes shall be scabbled, to remove the
concrete softened by the “Redalon” and to produce a hard rough surface in the hole.

All forming material and debris shall be completely removed from core holes and pockets
before the work shall be deemed completed. No holes will be permitted in cocnrete

Page 47 of 60
 members, other than for from bolts, unless shown or specifically approved by the
Superintendent.

Unless otherwise specified or approved all holes and openings shall be formed and all
inserts cat in place at the time of concreting. No part of the work shall be drilled or cut
away without the approval of the Superintendent.

5.2.24 Anchor Bolts

Anchor bolts shall be Grade 4.6, 8.8 or threaded high strength reinforcing bar as specified
on the Drawings. Under no circumstanes shall be Grade 8.8 anchor bolts be heated, nor
shall any attachments be made to them by means of welding.

All anchor bolts and cast-in fittings shall be hot dip galvanised in accordance with section
4.2.12, System C, of this specification.

Anchor blts shall whereever possible, be cast-in in position when the concrete is being
placed. The use of a localised void former around individual bolts (max size 50x50x150
deep) to assist in aligning the bolts is permitted providing the void former and any
laitance is thoroughly removed prior to grouting the base plate. At the discretion of the
the Superintendent, bolts for minor members such as ladders and cable tray support
brackets may later be grouted into holes cored or drilled in the concrete. All bolts shall be
set truly vertical or horizontal.

The thread of all anchor bolts shall be protected during concreting operations by coating
with a non-soluble grease and wrapping with hessian and tying.

The hessian shall be removed after the concreting is completed, the thread shall be
cleaned out and, together with the nut and washer, thoroughly greased to prevent
rusting, and the hessian replaced.

Anchor bolts shall be positioned within the following tolerances:

a) Location of centroid of a group of bolts + - 10mm

b) Location of bolts relative to each other + - 2mm
c) RL of top of holdingdown bolts + 12mm – 3mm

5.2.25 Joint Fillers

Joint fillers shall be supplied and fixed in a pre-formed condition to each joint where
specified.

Oint filler in tied or dowelled joints between adjacent independent slabs shall be bitumen
impregnated fibre borad.

Joint fillers in expansion or rotation joints shall be closed cell polyethylene foam joint filler
fixed to the concrete already cast using an approved adhesive.

Page 48 of 60
 Where joint sealants are to be applied, joint fillers shall be supplied pre-slit to the
dimensions necessary to facilitate removal of excess filler prior to installation of the joint
sealants

The Contractor shall submit details of all products proposed for use in the works, for the
approval of the Superintendent, prior to work commencing.

5.2.26 Joint Sealants

Sealants for joints in non trafficked horizontal and vertical faces shall be a multi
component epoxidised polyurethene.

All joint sealants shall be formulated, mixed and applied strictly in conformity with the
manufacturer’s requirements.

The recesses for the sealants shall be primed with an approved primer, applied strictly in
accordance with the manufacturer’s instructions, prior to the application of the sealing
compound.

Details of all proposed sealants shall be submitted to the Superintendent for approval
before being used in any joint.

Where practicable, sealing compounds shall be applied not less than 28 days after placing
of the last concrete in contact with them, but prior to the handing over of the area for
occupation or use by others.

5.2.27 Water-stops
The Contractor shall supply and cast in place water-stops in accordance with the
requirements of this Specification and the details shown on the drawings.

All water-stops shall be of the same material and of symmetrical section. A sample profile
of each type or pattern of water-stop shall be submitted to the Superintendent for
approval before being used.

All water-stops shall be 250mm wide PVC extruded from virgin polyvinyl chloride
containing no reclaimed or srap material and shall be homogenous, free from porosity
and other imperfections, and shall comply with BS 2571 Grade G4 Class 3.

All intersections shall be factory moulded so that butt splices only are made on site. After
splicing, all beads and excess material shall be cut back flush with the adjacent surface. All
splicing equipment shall be submitted for approval by the Superintendent, and splicing
shall be carried out strictly in accordance with the manufacturer’s instructions. All field
butt splices shall be fused using electric heating equipment supplied by the manufacturer
of the water-stop for the purpose.

All water-stops shall be securely held in their correct positions during placing of the
concrete. No holes shall be made through any water-stop, except where special webs are
provided for this purposes. Care shall be excerside in compacting concrete around water-
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 stops ensure that no voids or porous areas are left in the finished work and that the
water-stop is not displaced from its true position.

5.3 Piling
5.3.1 Extent of Works
The work described in this section includes the supply of all metarials, labour, plant and
equipment, delivery, installation and testing of tubular steel piles and precast concrete
piles including cutting off to the required level and head preparation as necessary, all as
shown on the drawings or specified.

5.3.2 Foundation Information

An investigation of the foundation conditions has been undertaken, and is documented in
the Site Investigation Report.

The strata information given is based on the nature of the samples recovered and on site
observations made during drilling. Where sampling is not continous, the samples
represent discrete observations of the overall subsurface profile. Attention is therefore
drawn to the frequency of sampling, the number of bores and the drilling method in the
interpretation of the investigation results.

The contractor shall visit the site to acquaint himself with the types of materials
encountered in the test bores.

Should material be encountered which in the opinion of the Contractor is radically

different and makes driving necesarrily difficult or not possible, such alternative methods
or techniques as may be necessary will be ordered by the Superintendent, who will in
addition, determine in negotiation with the Contractor, the value of price variation to the
lump Sum Tender price occasioned by these matters.

Notwithstanding the above procedures, it is the duty and responsibility of the Contractor
to:

 Carefully examine the results of the foundation investigation

 Note the variability of strata likely to be encountered, in particular the presence
of sand clays and gravels
 Critically assess plant requirements and pile driving techniques on the basis of the
above information in order to achieve pile penetrations consistent with the
provisional pile lengths as specified on the drawings

The Contractor shall be deemed to have allowed in his tender for all works necessary in
order to achieve the pile penetrations nominated on the Drawings, taking into account his
duties and responsibilities to assess the site conditions as specified above or which could
be reasonably anticipated at the date of Tender by a Contractor experienced and
competent in carrying out work of this type.

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 The Contractor is deemed to have:

 Visited the site and made all necessary effort to determine the site conditions as
they apply to piling
 Examined soil samples taken from the borings and related these to the
descriptions given in the results contained in the Site Investigation Report
 Critically assessed the evaluation of foundation conditions as representedin the
borelogs given in the Site Investigation Report
 Accepted the obligation to drive piles to the provisional lengths shown on the
drawings or the depth approved by the Superintendent

5.3.3 Materials

5.3.3.1 Concrete
Concrete compressive strength of bored piles shall have minimum 29.05 Mpa (K350) at
28 days age unless noted otherwise on the drawing, requirement of concrete material
shall be accordance with section 4.3. For precast concrete piles, Concrete shall be grade
K 500 (fc’ = 50 Mpa).

The contractor shall provide details of the concrete mix to be used for approval prior to
commencing work. Once approved, the mix design shall not be altered without approval
from the Superintendent.

All concrete shall be ready mixed, transported and placed in accordance with AS 1379 –
specification and Supply of Concrete and AS 3600.

5.3.3.2 Reinforcement
All reinforcement shall consist of plain and deformed bars complying with AS 1302 –
steel reinforcing bars for concrete.

All reinforcement shall be installed as an assembled unit bars securely tied together.
Should the welding of bars be contemplated, permission shall be obtained from the
Superintendent before ptoceeding and all welding shall comply with AS 1554.3 –
Welding Reinforcing Steel.

5.3.3.3 Admixture
All kind of admixture will be used in the work shall be approved by the Engineer.
Admixtures which contain of chloride or nitrate shall not be used. Admixtures shall be
stored in container and protected to prevent damage.

5.3.4 Pile Capacity and Pile Set

The Contractor shall calculate the final set and submit his calculations to the
Superintendent prior to pile driving commences. Calculations shall be resubmitted if site
measurements differ from the original assumptions.

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 Required values of final set shall be calculated using the following version of the Hiley
Formula, using the actual equipment, cooficients for temporary compressions, efficiency
of blow, etc, measured on Site.

[ + e ( + )] E
= 9800 − 0.5
( + + )

S = pile set in milimitres

Mm = mass of the falling part of the hammer in tonnes

Mf = mass of pile helmet for drop hammers or combined mass of pile helmet plus an
for steam, air or diesel hammers in tonnes

Mp = mass of pile in tonnes

E = energy input per blow in tonne metre as calculated in accordance with ClauseI.9

e = coefficient of restitution

= 0.25 for 300mm hardwood packing (acting alone) or

= 0.40 for 100mm of novasteen (acting alone)

K = minimum ultimate capacity of pile in kilo-newtons stated in the drawing

C = combined temporary compression of the helmet cushion(s), pile and adjacent

ground in milimetres

5.3.5 Construction Requirements

5.3.5.1 Drilling
 When bored pile is required, the ground at the proposed pile location shall be
drilled with an approved drilling machine, enable to drill hole to the required
diameter using temporary casing (if necessary). The equipment shall be
equipped with cutting tools and capable of drilling through water bearing
stratum, boulders, shales, stiff clays, gravels and sand.
 Drilling work shall be conducted from the ground surface through specified dept
on the drawing.
 In case of the borehole side are likely to rupture, temporary steel casing of the
same size diameter and length with minimum 6mm thick shall be installed. The
joint on the casing should be reasonably watertight. The usage partial or full
casing shall be the contractor’s responsibility. Wheneever the vibration method
is used for taken out the casing, contractor should ensure that will not disturb
the existing utilities and all additional cost be borne by the contractor.
 Inflow of soil and ground water may also be controlled by the use of a head of
water or drilling mud. The water or mud level inside the drilling should be
maintained not less than 1.50m above the natural ground water level and not
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 more than 0.90m below the top of the hole, these precautions should be
maintained until drilling work is finish.
 Drilling record for each pile shall be done properly
 Any looses materials and sediment on the bottom of borehore likely affect the
performance of bored pile should be removed to the satisfaction of the
Engineer.

5.3.5.2 Reinforcing
 Reinforcing steel shall consist of plain and deformed bars complying with AS
1302
 The contractor shall provide reinforcement steel cage in accordance with the
drawings, included the type, dimensions and length of each part of the element,
splice and so on, in case the construction method proposed by contractor
requires additional reinforcement, the cost shall be borne by the contractor.
 Reinforcement cage shall be supported centrally and firmly within the borehole
so that no movement occurs during concreting.
 Minimum concrete cover to reinforcement is 75mm unless noted on the
drawings
 Construction tolerance shall be as follow:
- Placing of reinforcement shall be in such concrete cover will be 75mm ±
6mm.
- Tolerance in spacing between re-bars ± 6mm.

5.3.5.3 Concreting
 All concrete works shall comply with AS1379 – Specification and Supply of
Concrete, unless noted otherwise.
 Concrete material shall comply in all respect with the standards unless specified,
excluded or modified hereafter. All material have been damaged, contaminated,
which are unidentified, shall be rejected and removed from the site immediately
and shall be in contractor’s expense.
 Measuring, mixing, transporting and placing of concrete shall be in accordance
with AS 1379
 For each of pile, minimum 3(three) cylinder sample should be taken for tested
on 7 days, 14 days and 28 days age. The test should be entrusted to an
independent laboratory.
 Concreting will not be allowed to commence until the bored hole has been
inspected by the Superintendent.
 Concreting shall be conducted after the drilling and cleaning is completed, right
after steel cage, tremie pipe and funnel are already installed and agreed by the
Superintendent. No borehole is allowed to be exposed overnight in case a cavity
in encountered the contractor shall purpose their method or pouring to avoid
exposure overnight.

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  During concreting the standing time from one bucket or mixer to the other shall
be safely smaller than the setting time of concrete.
 Tremie pipe used shall have minimum diameter of 200mm and the receiving
hopper shall have a capacity of at least equal to pipe it feeds.
 Tremie pipe shall be positioned at all time during concreting in such a way so
that the bottom of the pipe is at least 1.50m below the level of the concrete at
every pouring stage.
 The tremie shall be extended to the bottom of the borehole. The joints shall be
made watertight by a gasket or other approved method.
 A sliding plug e.g wire mesh covered by plastic sheet, which will be pushed
down the pipe by the weight of concrete shall be placed in the pipe’s head of
the first charge to prevent the concrete mixing with the water in the pipe.
 A means of sounding shall be provided to check the level of the concrete surface
and ensure that the pipe is buried to a sufficient depth to maintain a seal and
control the flow of concrete.
 The concreting for bored pile to be vertically tested shall be conducted until the
top of the pour is 1.0m above the ground surface.
 The actual volume of concrete used shall be recorded and checked with the
calculated volume required to indicate the possible of necking or caving in the
bore hole. Concrete head measurement is required. “As built pile profile” should
prepare which showing the over pile diameter for every concrete pouring stage.
 After finish concreting, the top level of Test pile shall be recoded and refer to
site bench mark.

5.3.6 Pile Splicing

Wherever practical, pile shall be supplied in the lengths required for driving. Splices, if
required shall be effected by qualified complete penetration butt welds to AS1554 or
approved equivalent made with a single or double V preparation, unless approved
otherwise.

Segments to be joined shall have their dimensions match as near as practicable.

Misalignment at splice welds shall not be permitted. All splices may be inspected by the
Superintendent prior to welding.

The rolerance on straightness of individual pile sections shall not exceed 1 mm per metre
of pile length up to a maximum tolerance of ±12mm.

After completion of casting, the concrete, piles shall be wet cured for a period not less
than 4 days.

Each pile shall be marked clearly and indelibly with its date of casting, length and
reference number on the top surface and head of pile immediately after casting.

Mechanical joints shall be provided between succesive lengths of pile to the approval of
the Superintendent. The Contractor shall be responsible for determining the length of

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 each section and the location of joints. Such joints shall be capable of transmitting the
specified ultimate tension and compression loads for the pile. The tops most section of
jointed piles shall be manufactured in the longest practicable lengths. Joints shall not be
positioned within 6 metres of the specified pile cut off level.

Any face of a plie shall not deviate by more than 6mm from a straight edge 3m long and
the centroid of any cross section of the pile shall not deviate by more than 12mm from
the straight line connecting the centroids of the end faces of the pile.

Concrete cover to reinforcing steel shall not be less than 50mm.

Where accelerated curing is used the curing procedure shall be subject to the approval of
the Superintendent. The temperature of the concrete shall not be raised until at least four
hours after completion of concrete placing. The rise in temperature within any period of
30 minutes shall not exceed 100C and the maximum temperature attained shall not
exceed 700c. The rate of subsequent cooling shalll not exceed the rate of heating.

5.3.7 Pile Toe Levels – Pile Acceptance

All piles shall be driven to “the calculated set”, as defined elsewhere herein. The
provisional toe levels defined on the drawings are the design Superintendent’s
assessment of the toe levels, taking into account borehole drilling information. The
Contractor is deemed to have allowed for in this Tender for all works needd in driving to
these toe levels under the assumption that “the calculaed set” will be reached at these
levels. Toe levels of actual driven piles will vary from these provisional levels and the
Superintendent will assess an acceptable toe level for each individual pile taking into
account all or some of the following factors:

a) The driving history of the pile

b) The driving resistance of the pile
c) The driving history of piles in adjacent locations
d) The tensile and compressive load required to be carried by the pile and adjacent
piles and their bending moments
e) The penetration of the pile in relation to design assumptions concerning fixity and
loads
f) The results of dynamic pile testing of this pile or adjacent piles

The Superintendent shall have the sole responsibility for final determination of the pile
founding levels during installation, and may order founding at a higher or lower level than
indicated on the Drawings, at his sole discretion.

5.3.8 Pile Driving Plant

The piles under this contract shall be driven by a diesel hammer, or other hammer type,
approved by the Superintendent. Drop hammers are not accepatable for the driving of
piles on this project. Hammers shall have a minimum rated energy capacity of 8 t/m per
blow.

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 For diesel hammers:

E = Er x e f

Where:

E = energy input per blow in tonne metres

Er = the manufacturer’s rating of energy output of the hammer in tonne metres

Ef = efficiency of the blow

= 0.85 for a hammer in good working condition

Pile hammers to be used shall be capable of driving the piles to the founding levels
required by the Superintendent. The Contractor shall allow for hammers working at
maximum energy level at low sets for sustained periods. The Contractor shall allow in the
rates submitted in the Tender for all wear and tear on the hammer or hammers
occasioned by driving in all situations except as specifically excluded in this Clause.

Leaders, anvils and helmets used shall be designed such that the ram strikes
concentrically on the heads of the piles. Helmet design and the number of hammers that
the Contractor deems necessary to carry out the work is the responsibility of the
Contractor. The number of hammers to be avalable on site shall be nominated in the
Tender.

The piles shall be adequately supported to ensure accurate alignment during pitching and
driving. The pile frames used shall have firmly supported guides extending down to the
lowest point to be reached by the hammer.

Pile driving plant to be used shall be capable of pitching and driving the provisional
lengths of piles in a single length.

Details of the size of the crane to be used to handle and pitch the piles shall be submitted
at the time of tender, together with details of pile frames, gates and leader proposed.

5.3.9 Handling of Piles

Handling, transporting, pitching and driving of the piles shall be carried out in such a
manner to ensure that piles are not damaged in any way.

5.3.10 Marking
All piles shall be clearly marked in 500mm intervals or as directed by the Contractor to
facilitate the making of a pilling record. Marking at 10mm intervals is required in that part
of the pile length where tighter driving sets are expected.

5.3.11 Pitching and Driving

The piles shall be set out to the alignment and centre position shown on the Drawing. The
piles shall be driven without stopping until the “calculated set” is reached.
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 The Contractor shall allow in his Tender Price for any strengthening of the heads of the
piles as may be necesarry to resist driving stresses, and for the use of a suitable helmet.
The hammer (or hammers) that the Contractor elects to use shall distribute the load
evenly into the pile by a suitably constructed helmed and packing materials.

If damage occurs at the heads of the piles, then it shall be the Contractor’s responsibility
to rectify this damage, at no additional cost to the Superintendent.

The Contractor shall allow for all repairs, damage to hammers and pile strengthening as
he considers necesssary and no claims for variations associted with his selection and
operation of pile driving equipment will be entertained.

5.3.12 Tolerances
The deviation of any pile centre from the setting out point shown on the drawings shall
not exceed 75mm in any direction.

The deviation of any pile shown as vertical on the drawings shall not exceed a slope of 1 in
100 from vertical.

The pilling rig shall be set and maintained to ensure that raking piles are installed to the
rakes shown on the drawings. The deviation of any raking pile shall not exceed a slope of
1 in 25 from the required rake shown on the drawings.

Forcible corrections to piles shall not be made.

Should any pile driven exceed these specified tolerances, the Superintendent may direct
that the Contractor extract, and/or drive a replacement pile or piles in the correct
position, at the expense of the Contractor.

5.3.13 Driving Record

The Contractor shall keep a record of the driving of each pile as instructed by the
Superintendent and shall submit this to the Superintendent not later than twenty-four
(24) hours after driving. Unless agreed otherwise by the Superintendent, no pile driving is
to take place without the Superintendent representative being present.

The record shall show the following information:

 Contract number
 Pile reference number
 Pile type
 Nominal cross-section dimension or diameter
 Length of preformed pile
 Date and time of driving
 Ground level
 Top level

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  Type, weight, drop and mechanical condition of hammer and equivalent
information for other equipment
 Number and type of packing used and type and condition of dolly used during
driving the pile
 Number of blows per metre for each metre of driving and height of hammer drop
 Set of pile or pile tube in mm per 10 blows or number of blows per 25mm of
penetration, the sets taken at intervals of 400mm during the last 3m of driving
 Temporary compression of ground and pile from time of marked increase in
driving resistance until pile reaches its final level
 All information regarding obstructions, delays and other interruptions to the
sequence of work

At the completion of pilling, the Contractor shall provide a complete survey of finished
pile level and plan location of each prepared by a registered surveyor.

5.3.14 Defective or Damaged Pile

If any pile is damaged beyond an acceptable standard, in the sole opinion of the
Superintendent, it may be condemned and a replacement ordered by the Superintendent.
Alternatively, the Superintendent may demand such remedial repairs as deemed
necessary. This shall be at the Contractor’s expense.

5.3.15 Pile Cut-Off

Piles shall be cut off neatly to within 10mm of the pile cut-off levels specified on the
drawings.

The heads of all piles shall be prepared in the manner shown on the Drawings.

5.3.16 Dynamic Pile Testing

The Contractor will be required to undertake dynamic testing on a maximum of three (3)
number piles in the works. The specific piles to be tested will be nominated by the
Superintendent, and will be spread throughout the pilling works, through some bias
towards the nearly part of the program is expected.

The Superintendent may order additional piles in any area of the works to be subject to
dynamic testing, the price variation is to be aggred in negotiation with the contractor.

The following measurements and analysis shall be carried out:

 Blow count for the entire driven penetration at metre intervals

 Stress wave measurements using the CASE method and Pile Driving Analyser as
manufactured by Pile Dynamics Inc, or approved equivalent
 Elastic compression at end of driving and final set
 Calculation of skin friction, point load and load deformation curve by CAPWAP
analysis

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The Contractor shall engage experineced specialist consultants to conduct the dynamic
pile testing. The proposed consultant’s name, the proposed testing equipmet, and
curricula vitae of staff to undertake testing shall be submitted to the Superintendent for
approval at least four (4) weeks prior to the commencement of testing.

A summary of field tests results shall be submitted to the Superintendent within twenty-
four (24) hours of completion of the testong. Results shall include the static resistance
mobilised, the permanent set per blow during dynamic testing, an assessment of pile
integrity and maximum pile stresses during testing. Within two (2) working days of
testing, the Contractor shall supply the results of CAPWAP analysis.

Dynamic testing will be by re-strike testing at least forty-eight (48) hours after initial
driving

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6 Contractor Supplied Drawings and Data
The Contractor is responsible for preparation of all drawings including preparation of
arranegements and shop fabrication drawings for all items included in this specification. The
Contractor shall supply to the Company two copies of all arrangement drawings.

The Contractor shall be solely responsible for all dimensions, and dimensional accuracy of the
works supplied under this contract.

The Contractor shall verify all dimensions drom the site and shall be responsible for the same
and any discrepancies in the drawings shall be brought to the attention of the Company
before fabrication commences.

6.1 As-Built Drawings

Prior to issue of the Certificate of Practical completion, the Contractor shall submit a
complete set of “As-Build” drawings. The As-Built drawings shall include all drawings
previously submitted, updated to “As-Built” status and all additional shop fabrication and
certified drawings as required to fully describe to the Asiatic Coal Terminal.

The drawings shall be in sufficient detail to enable purchasing of replacement components

and/or planning or repair procedures to be undertaken by the Company without the
necessity of dismantling or measuring any part of the part of the plant to obtain details of
materials, dimensions and clearences.

“As-Build” drawings shall be endorsed accordingly and shall be issued to the Company in
the following forms:

 CD for all drawings produced in an electronic format

 2 sets of full size prints

6.2 Drawing Format

Drawings shall be prepared on a computer drafting system. Copies of drawings provided on
digital electronic media shall be suitable for reading and editing using “AUTOCAD”
software. An electronic copy of each drawing submitted shall be provided to the Company.

CAD drawings shall be prepared using the Company layering and text standards. The
Contractor shall request details of these standards prior to commencement of drafting.

Manually prepared drawings may be accepted subject to approval by the Company.

All drawings shall be prepared in A1 with scales suitable to be seen in A3 size. All
information shall be in the English language and all dimensions shall be in SI metric units.

All drawings shall be numbered in a logical sequence. The Company numbering system shall
be used and shall be requested by the Contractor prior to commencement of drafting.

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