Jebel Ali Power Station ‘K’ Phase III Civil Works RFx No. 2131600023

RFx No.
: 2131600023
Jebel Ali Power Station K Phase III
Volume II
(GENERAL PROJECT REQUIREMENTS)
Part G05.4
Civil Works
Dubai Electricity and Water Authority

P.O. Box 564
Dubai
United Arab Emirates
April 2016
RFx No.: 2131600023

Issue and Revision Record

Rev
0
Date
Originator
11/04/2016 Mlderink
Checker
Schultz
Approver
Rner
Description
Issued for Tender
Volume II, Part G05.4

Civil Works
Table of Contents
1
General ....................................................................................................................... 7
1.1
Scope of Work, Completeness .................................................................................... 7
1.2
Civil Design/Engineering ............................................................................................. 7
1.3
Codes and Standards .................................................................................................. 7
1.3.1
American Standards: .................................................................................................. 7
1.3.2
European Standards: .................................................................................................. 8
1.3.3
Local Standards and Regulations ................................................................................ 8
1.3.4
Other Standards.......................................................................................................... 9
1.4
Design Criteria for Layout, Arrangement, Drawings, Execution ................................. 9
1.4.1
Basic Requirements for All Civil Works....................................................................... 9
1.4.2
Design Loads / Load Assumptions ............................................................................ 11
1.4.3
Tolerances................................................................................................................. 14
1.4.4
Special Requirements for Materials To Avoid Corrosion Problems Reinforced

Concrete ................................................................................................................... 15
1.4.5
Special Requirements for Materials to Avoid Corrosion Problems Steel

Structures ................................................................................................................. 16
1.5
Materials (Quality, Delivery, Storage, Handling) ...................................................... 17
1.5.1
General ..................................................................................................................... 17
1.5.2
New /Unused Materials ............................................................................................ 17
1.5.3
NA ............................................................................................................................. 18
1.5.4
Samples..................................................................................................................... 18
1.5.5
Supplier/ Material Approval Procedure ................................................................... 18
Site Installation and Demobilisation ......................................................................... 19
2.1
Scope of Work, Completeness .................................................................................. 19
2.2
Execution (Assembling, Installation) ........................................................................ 19
Site Supervision/Survey/Investigations .................................................................... 20
3.1
Site Supervision: ....................................................................................................... 20
3.2
Survey and Investigations ......................................................................................... 21
Dewatering During Construction .............................................................................. 22
4.1
QA/QC ....................................................................................................................... 22
Site Clearance and Earth Work ................................................................................. 24
5.1
Site Clearance- General ............................................................................................ 24
5.2
Earth Works, Completeness ..................................................................................... 24
5.3
5.3.1
Select Fill ................................................................................................................... 25
5.3.2
Ordinary Fill .............................................................................................................. 25
5.3.3
Special fill .................................................................................................................. 25
5.4

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5.4.1
Safety Precaution...................................................................................................... 25
5.4.2
Stockpiles and Disposal ............................................................................................ 26
5.4.3
Preparation of Foundations ...................................................................................... 26
5.4.4
Backfilling .................................................................................................................. 26
5.4.5
Soil Replacement ...................................................................................................... 27
5.4.6
Pipe Bed Preparation ................................................................................................ 27
5.4.7
Protection of Existing Utilities and Services ............................................................. 27
5.4.8
Deep Vibratory Techniques ...................................................................................... 28
5.4.9
Dust Control .............................................................................................................. 28
5.5
QA/QC, Test and properties ..................................................................................... 28
5.5.1
General ..................................................................................................................... 28
5.5.2
Quality Assurance for Vibro Techniques .................................................................. 29
Piling Works .............................................................................................................. 30
6.1
Documents to Be Submitted .................................................................................... 30
6.2
Design Criteria, Arrangement Drawings ................................................................... 30
6.2.1
Bored Cast-In-Place Piles and Driven Piles ............................................................... 30
6.3
6.3.1
Steel Reinforcement and Concrete .......................................................................... 31
6.4
6.4.1
Program .................................................................................................................... 32
6.4.2
Qualification ............................................................................................................. 32
6.4.3
Staking-Out Tolerances............................................................................................. 32
6.4.4
Cut-off ....................................................................................................................... 32
6.4.5
Working Platform ..................................................................................................... 32
6.4.6
Concreting................................................................................................................. 33
6.5
QA/QC ....................................................................................................................... 33
6.5.1
Piling Record ............................................................................................................. 33
6.5.2
Test Piles, Static Loading Tests ................................................................................. 34
Concrete Work .......................................................................................................... 36
7.1
7.2
Civil Design/Engineering ........................................................................................... 36
7.3
Dimensional tolerances ............................................................................................ 36
7.4
Concrete with Special Properties ............................................................................. 36
7.4.1
General Requirements.............................................................................................. 36
7.5
Finishing Of Concrete Surfaces ................................................................................. 38
7.6
Bar-bending Schedules ............................................................................................. 38
7.7
Crack Widths of reinforced Concrete Structures...................................................... 38
7.8
7.8.1
Quality of Materials .................................................................................................. 38
7.8.2
Storage of Materials ................................................................................................. 39

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7.8.3
Cement ..................................................................................................................... 39
7.8.4
Water ........................................................................................................................ 39
7.8.5
Aggregates ................................................................................................................ 39
7.8.6
Reinforcement, Treatment and Coating of Reinforcement ..................................... 41
7.8.7
Concrete mixes ......................................................................................................... 42
7.8.8
Transport of Concrete .............................................................................................. 43
7.8.9
Concreting Operations.............................................................................................. 44
7.9
QA/QC ....................................................................................................................... 47
7.9.1
Trial Mixes................................................................................................................. 47
7.9.2
Quality and Testing ................................................................................................... 48
7.9.3
Strength of Concrete ................................................................................................ 48
7.9.4
Reinforcement Certificates .................................................................................... 49
7.9.5
Shuttering and Scaffolding Works ............................................................................ 50
Pre-cast Concrete ..................................................................................................... 51
Grouts ....................................................................................................................... 52
10
Masonry, Mortar, Plaster ......................................................................................... 53
10.1
10.1.1
Cement Mortars ....................................................................................................... 53
10.1.2
Masonry .................................................................................................................... 53
10.1.3
Plaster ....................................................................................................................... 54
10.2
Execution .................................................................................................................. 55
11
Steel Work ................................................................................................................ 56
11.1
Civil Design/Engineering ........................................................................................... 56
11.2
Design Criteria for Layout, Arrangement, Drawings, Execution ............................... 56
11.2.1
General ..................................................................................................................... 56
11.3
Materials ................................................................................................................... 57
11.3.1
General ..................................................................................................................... 57
11.3.2
Steel Specifications ................................................................................................... 57
11.3.3
Galvanizing................................................................................................................ 58
11.4
Execution /Workmanship ......................................................................................... 58
11.4.1
Tolerances................................................................................................................. 58
11.4.2
Connections .............................................................................................................. 58
11.4.3
Painting ..................................................................................................................... 61
11.4.4
Erection ..................................................................................................................... 61
11.5
QA/QC ....................................................................................................................... 63
12
Small Non-Structural Steel Parts .............................................................................. 64
12.1
General ..................................................................................................................... 64
12.2
Design /Engineering.................................................................................................. 64
12.2.1
Steel Sections and Plates .......................................................................................... 64
12.2.2
Chequered Plates...................................................................................................... 64

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12.2.3
Metal Flooring .......................................................................................................... 65
12.2.4
Steel Grating ............................................................................................................. 65
12.2.5
Ladders ..................................................................................................................... 65
12.2.6
Steel Stairs ................................................................................................................ 66
13
Waterproofing .......................................................................................................... 67
13.1
General ..................................................................................................................... 67
13.2
Roof drains ................................................................................................................ 67
13.3
Rainwater/Gutter down pipes .................................................................................. 68
14
Metal Works Roof and Wall Cladding Systems...................................................... 69
14.1
14.2
Warranties ................................................................................................................ 69
14.3
Codes and Standards ................................................................................................ 69
14.4
14.4.1
Wall and Roof Cladding System ................................................................................ 70
14.4.2
Requirements for Walls ............................................................................................ 71
14.4.3
Requirements for Roofs ............................................................................................ 72
14.5
14.5.1
Sunshades ................................................................................................................. 73
14.6
14.6.1
Supporting Structure ................................................................................................ 74
14.6.2
Fasteners .................................................................................................................. 74
15
Metal Works /Joiners Work Doors ....................................................................... 76
15.1
15.1.1
General ..................................................................................................................... 76
15.1.2
Fire Steel Doors......................................................................................................... 76
15.1.3
Roller Shutter Doors ................................................................................................. 77
15.1.4
Profile Cylinders ........................................................................................................ 78
15.1.5
Master-Key System ................................................................................................... 78
15.1.6
Building and Room Designation Signs ...................................................................... 78
16
Metal Works /Joiners Works Windows and Doors ............................................... 80
16.1.1
Aluminium windows ................................................................................................. 80
16.1.2
Ventilation louvers.................................................................................................... 80
17
Glazing ...................................................................................................................... 81
17.1
17.1.1
Noise levels ............................................................................................................... 81
17.2
17.2.1
General ..................................................................................................................... 81
17.2.2
Double Glazing Units ................................................................................................ 81
17.2.3
Seal Strips ................................................................................................................. 82
17.2.4
QA/QC ....................................................................................................................... 82

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18
Suspended Ceilings ................................................................................................... 83
18.1
Scope of Work, Completeness.................................................................................. 83
18.2
Material .................................................................................................................... 83
18.3
19
Flooring ..................................................................................................................... 84
19.1
19.2
19.2.1
Bonded Cement Screed ............................................................................................ 84
19.2.2
Raised Floors ............................................................................................................. 84
19.3
19.3.1
General ..................................................................................................................... 86
19.3.2
Protection of Flooring ............................................................................................... 86
20
Tiling ......................................................................................................................... 87
20.1
20.1.1
Ceramic floor and wall tiles ...................................................................................... 87
20.1.2
Acid-proof Tilling Material ........................................................................................ 88
20.2
20.2.1
Preparation of Surface .............................................................................................. 88
20.2.2
Placing....................................................................................................................... 88
21
Painting ..................................................................................................................... 90
22
Plumbing and Drainage Installation ......................................................................... 91
22.1
General ..................................................................................................................... 91
22.2
Materials ................................................................................................................... 91
22.2.1
General Requirements.............................................................................................. 91
22.2.2
Drainage Wares & Fittings ........................................................................................ 92
22.3
Execution of Work .................................................................................................... 93
22.3.1
General ..................................................................................................................... 93
22.3.2
Pipes and Fittings ...................................................................................................... 93
22.3.3
Jointing of Pipes ........................................................................................................ 94
22.3.4
Placing of Sanitary Fixtures....................................................................................... 94
22.3.5
Earthing of Metal Parts ............................................................................................. 94
23
Roads and Pavements, Outdoor Facilities ................................................................ 95
23.1
23.2
Sub-grade .................................................................................................................. 95
23.3
Sub-Base ................................................................................................................... 95
23.4
Wet Mix Road Base................................................................................................... 96
23.5
Bitumen Macadam Layers General........................................................................ 97
23.5.1
Design of Bitumen Macadam Layers ........................................................................ 98
23.5.2
Mixing and Placing of Bitumen Macadam Layers ................................................... 100
23.6
Chlorides and Sulphates ......................................................................................... 101

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23.7
Hard Shoulders ....................................................................................................... 101
23.8
Testing of Material, Field Tests............................................................................... 101
23.9
Jointing New to Existing Pavement ........................................................................ 101
23.10
Fencing and Gates .................................................................................................. 102
23.10.1
Steel Fencing Posts ................................................................................................. 102
23.10.2
Chain Link Wire-Mesh............................................................................................. 102
23.10.3
Gates ....................................................................................................................... 102
23.11
Landscaping ............................................................................................................ 103
23.11.1
Products and Material (NOT APPLICABLE) ............................................................. 103
23.12
Interlocking Paving Blocks ...................................................................................... 103
23.13
Kerbs ....................................................................................................................... 104
23.14
Traffic Signs ............................................................................................................. 104
23.15
Carriageway Markings ............................................................................................ 105
23.16
Guard Rails .............................................................................................................. 105
23.17
Temporary Traffic Signs and Carriageway Markings .............................................. 105

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General
The Tenderers are requested to propose high energy efficiency buildings and shall propose energy
saving constructions for slabs, walls, windows, doors and roofs according to local or international
standards whichever is more stringent and with special reference to Green Buildings Regulations and
Specifications. The requirements stated herein are to be followed together with all the relevant detailed specifications in civil-, electrical-, mechanical- and I&C-disciplines.
1.1
Scope of Work, Completeness
This specification covers the general technical requirements of civil works. The design and execution
shall be state of the art, functional and complete in all parts.
1.2
Civil Design/Engineering
The design and engineering shall be state of the art in accordance with all relevant codes and standards, functional and complete in all aspects. .
Before starting the design works, the Contractor shall submit to the Employer/Engineer for review the
project design manual containing design data, and detailed design criteria for all civil works. Design
works shall commence only after review of the project design manual by the Employer/Engineer.
The reinforced concrete design and working drawings of main structures (concrete buildings and steel
structures including shop drawings and connection details) shall be submitted by the Contractor for
approval by the Employer/Engineer. Soft copies of all designs and structural calculations shall be submitted along with all models and diagrams.
All main routings (culverts /tunnels /trenches /duct banks /ducts) shall be submitted by the Contractor
for approval by the Employer/Engineer.
1.3
Codes and Standards
The design, all materials, civil works constructions and installations, tests and investigations , must be
as a minimum conform to the latest edition of the following Codes and Standards (listed in alphabetical
order) as far as these standards, codes and regulations are available in an English language edition.
1.3.1
American Standards:
American National Standard Institute
(ANSI)
American Society for Testing and Materials
(ASTM)
American Concrete Institute
(ACI)
American Institute of Steel Construction
(AISC)
American Iron and Steel Institute
(AISI)

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American Water Works Association
(AWWA)
Uniform Building Code
(UBC)
American Welding Society
(AWS)
American Association of State Highway and

Transportation Officials
(AASHTO)
National Plumbing Code
(NPC)
American Society of Civil Engineers
(ASCE)
Portland Cement Association
(PCA)
National Concrete Masonry Association
(NCMA)
Occupational Safety & Health Administration
(OSHA)
1.3.2
European Standards:
European Norm
(EN)
International Organization for Standardization (ISO)
British Standards
British Standard
(BS)
British Standard Code of Practice
(BS CP)
German Standards
Deutsches Institut fr Normung eV
(DIN)
Verein Deutscher Ingenieure
(VDI)
1.3.3
Local Standards and Regulations
Construction Industry Research and Information Association
(CIRIA)
Dubai Municipality Coastal Zone Regulations

Other local standards and national regulations, if any
Building regulations and guide lines by the Dubai Municipally, if any
Local Green Buildings Regulations

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1.3.4
Other Standards
Other internationally accepted standards which ensure a quality equivalent to or higher than the
standards listed above may be used for specific works, but only if these are submitted in an English
language edition and approved by Employer/Engineer.
Japanese Industrial Standards
(JIS)
Swedish Standards for sand blasting of steel parts

Center for Civil Engineering Research and Codes
(CUR)
CUR /CIRIA Reports and Manuals

If any standard contains a provision which is inconsistent with a provision in another standard, the
more stringent shall apply.
1.4
Design Criteria for Layout, Arrangement, Drawings, Execution
1.4.1
Basic Requirements for All Civil Works
The design of all structures shall be such that differential and total settlements or other movements
shall not exceed the limits given by specifications or with the applicable codes, and standards and full
provision shall be made for all expansion and other joints.
Safety against uplift has to be guaranteed during all execution stages, especially when ground water
lowering is terminated. The factor of safety (FoS) against uplift shall be not less than 1.2.
Structural members subjected to flexure shall be designed to have adequate stiffness to limit deflections or any deformations that affect strength or serviceability of a structure adversely as per the specified criteria or the limits prescribed by the machinery manufacturers (whichever is less).
The superstructures and foundations subjected to vibrations (the primary source of these vibrations
being the unbalanced forces generated by rotating or reciprocating equipment) shall be designed such
that vibrations will be neither intolerable nor troublesome to personnel, and will not cause damage to
the machine or structure.
The natural frequency of the whole of the superstructures and foundations or parts thereof and all
structures adjacent thereto shall not coincide with the operating frequency of the vibrating plant. The
differences between frequencies and the dynamic analysis of the superstructures and foundations
shall be in accordance with the relevant design standard.
The dimensions of all the buildings shall be such as to provide adequate space for the safe installation
and proper operation, maintenance and repair of all plant and equipment.
Throughout the works all floor slabs above rooms containing electrical equipment shall be watertight.
No drain pipes or water pipes are permitted to pass through these rooms. If this cannot be avoided
civil design shall consider double slab with enough accessible space in between.

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All materials used in the Works shall be of the best quality of their respective kinds as specified herein,
obtained from sources and suppliers approved by the Employer/Engineer or his representative and
shall comply strictly with the tests prescribed hereinafter or, where tests are not laid down in this
Specification, with the requirements of the latest issue of the relevant American, British, German
Standards or other Standards agreed by the Employer/Engineer. Samples of all materials proposed to
be used in the works shall be collected from site for testing at any time by the Employer/Engineer.
Access roads with footpaths shall be provided to bring in all the equipment and to take it out in case
of maintenance. These access roads shall be suitable for the vehicles which will be used (cars, forklifts,
trucks/trailers acc. DIN 1072) to reach up to the point of unloading of the equipment.
All platform, galleries and stairways will be provided with guard rails and kick plates on all sides.
No flights will have more than fourteen (14) risers. Where a stairway height exceeds 14 risers, it shall
be divided in to equal flights separated by a landing. The minimum clear width of staircase is 100 cm.
Suitable access to the roofs of the buildings by means of galvanized and painted steel stairs shall be
provided for maintenance and repair of any installation.
All rooms subject to fire hazard shall be provided with emergency exits in accordance to local laws,
NFPA regulations and/or the applicable codes and standards. Hindrance free fire escape paths will not
be longer than 30 m nor less than 1.0 m wide to the nearest fire escape exit. However, erection routes
and doors will be dimensioned in all directions 0.3 m greater than the biggest part which has to be
transported, together with its transportation means.
Safe, convenient and straight forward accesses and means are to be provided to take equipment in
and out of all rooms, at all levels using suitable stair wells and suitable electric hoists. The dimensions
of rooms, stairwells, doors and corridors shall be designed to suit the above mentioned transport concept. Storage of cylinders or any other equipment in corridors and along any access route is not permitted.
Roof parapet height of all steel or concrete building structures shall be designed for a minimum height
of 1.2 meters.
If a culvert(s), and /or tunnel(s), trench(es) or any other underground services are crossing roads, the
road shall be suitably constructed for truck loading according to DIN 1072 without affecting the underground structures.
All pipe penetrations through water retaining structures/cable trenches/cable tunnels/cable pits and
manholes shall be furnished with buddle flanges. Approved type of PVC water bars shall be provided
for any underground construction/expansion joints.
All civil designs and drawings, inclusive all steel designs and drawings shall be approved by the Dubai
Municipality before start of construction. If the Contractor and/or his Subcontractor(s) starts with the
production of constructive elements off site and/or on site, before that approval was given, all changes
in Contractors work caused by disapproval and/or remarks will be fully on Contractors risk in costs
and time delay.

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Pedestals and foundations of outdoor equipments or partially shaded shall be designed minimum
0.30m above finished ground level.
All outdoor equipment shall be provided with sunshade as specified hereafter.
Before commencing the works the Contractor shall ascertain the locations and nature of all existing
underground services and shall take every possible precaution against any damage occurring to them
or interference therewith, during the execution of the works.
1.4.2
Design Loads / Load Assumptions
The following design loads shall be considered for the design of buildings and structures:
Area
Live load for building roofs
(A/C equipment and foundations to be considered additionally)
Sloping Roof-sheet metal construction
Operation Floors- Ground Floor
Operation Floors- Upper Floor
Switchgear Rooms, etc.
Battery Rooms
Workshop Floors- Ground Floor
Workshop Floors- Upper Floor
Light platforms, Walkways, Stairways :
Concrete
Steel
Additional dead load for suspended ceiling, pipes, AC system, etc.
Traffic Loads
Roads and pavements, gutters
Underground water tanks, septic tanks, etc. covered by road areas
Value
2.5
Unit
kN/m2
1.5
kN/m2
35.0
kN/m2
17.5
kN/m2
10.0
kN/m2
15.0
kN/m2
25.0
kN/m2
15.0
kN/m2
5.0
kN/m2
5.0
kN/m2
1.0
kN/m2
SLW 60, DIN 1072
SLW 60, DIN 1072
SLW 60, DIN 1072
Areas designated for different loadings on the same floor shall be clearly and permanently marked.
1.4.2.1 Dead Load

Dead load is defined as the weight of all permanent construction including walls, foundations, floors,
roofs, ceilings, partitions, stairways, and fixed service equipment.
For heavy industrial work, this would include equipment, vessels, including internals, pipes, valves, and
accessories, electrical and lighting conduits, switchgear, instrumentation, fireproofing, insulation; ladders, platforms, and other similar items.
Equipment and piping should be considered empty of product load when calculating dead load. The
gravity weight of soil overburden shall be considered as dead load.

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1.4.2.2 Erection Dead Load

The erection dead load is the weight of the equipment at time of erection plus the weight of the foundation. The foundation weight is the combined weight of the footing, pedestal, and overburden soil.
1.4.2.3 Live Load

Live load is defined as the weight superimposed by the use and occupancy of the building or other
structure, but not permanently attached to it. For industrial design, live load can be defined as the load
produced by personnel, moveable equipment, tools, and other items placed on the structure, but not
permanently attached to it.
Crane loads shall be considered as live load. Unless specified otherwise, the minimum live load values
given in Table 1 below shall be considered.
The loads assumptions quoted in Table 1 below have proved useful in the construction of numerous
power stations and are to be regarded as minimum requirements.
The Employer/Engineer's consent is required in all cases for reductions of load carrying capacities and
for exceeding the permissible stresses.
1.4.2.4 Product Load

The load shall be defined as the gravity load imposed by liquid, solid, or viscous materials in vessels,
tanks, equipment or piping during operation.
1.4.2.5 Test Load

The test load shall be defined as the gravity load imposed by any method necessary to test vessels,
tanks, equipment or piping.
1.4.2.6 Thermal Load

Thermal loads shall be defined as forces caused by changes in temperature. The primary source of
thermal loads in an industrial plant is the expansion or contraction of vessels and piping. Another
source of thermal loads in a redundant structure is the expansion or contraction of the entire structure
or individual structural components.
1.4.2.7 Impact Load

Any live load that can produce a dynamic effect (such as a moving load) shall be increased by an impact
factor.
1.4.2.8 Truck Load

Structures accessible to trucks shall be designed to withstand the gravity, lateral and impact effects of
truck loading. Truck loading shall be SLW 60 as defined by DIN 1072. However, when actual expected

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vehicles produce more severe load conditions (heaviest loads of equipment that will be transported)
they shall govern.
1.4.2.9 Soil Load

Soil loads shall consist of lateral earth pressures. Active and passive coefficients for lateral pressures
shall be obtained from the project soils report. The weight of soil shall be considered as dead load.
1.4.2.10 Hydrostatic Load and Buoyancy

Hydrostatic load is the load due to water pressure. The design of structures shall include hydrostatic
loads when applicable. The buoyancy load is equal to the weight of the volume of displaced water.
1.4.2.11 Wind Load

All wind calculations shall be made in accordance with the relevant British Standard using the following
factors:
Basic wind speed at 10 meters above ground
= 160 km/h (100 mph)
Exposure Category
=D
Importance factor, I
= 1.15
1.4.2.12 Earthquake Load

All buildings and structures shall be verified against earthquakes considering seismic zone 2B of UBC
or any latest local regulations requirements.
1.4.2.13 Dynamic Loads

Each structure shall be designed to withstand the effects of vibration and impact to which it may be
subjected. Each structure and foundation supporting a compressor, turbine, pump or other machinery
having significant dynamic unbalance shall be designed to resist the peak loads specified by the manufacturer. Vibration amplitudes of the supporting structure or foundation shall be kept within acceptable limits for dynamic forces that occur during normal machine operation. In the case of a tall and
slender structure, there may be a need to investigate the dynamic effects of wind gusts.
1.4.2.14 Surge Load

Surge loads may occur in some vessels or equipment. In such cases, the magnitude and direction of
the load shall be given by the equipment supplier.
1.4.2.15 Bundle Pull Loads

The force requirements to remove the tube bundle from a shell and tube heat exchanger may vary
from zero for those vessels in which the removal is done by application of hydraulic pressure resulting
in no external reaction to 1 - 1/2 times the weight of the bundle for external pull. The variation is due

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to the unpredictable coefficient of friction existing between the shell and the tube supports after the
exchanger has been in operation. The usual practice, if applicable, is to use one-half the weight of the
bundle for exchangers in clean service, but not less than 1,000 kg.
1.4.2.16 Future Load

Loads from future expansion shall be considered when so directed by the Employer/Engineer. Future
loads may include any of the loads listed above.
1.4.2.17 Miscellaneous Loads

Miscellaneous loads shall be defined as loads that do not fit into the categories listed in this clause.
Typical miscellaneous loads are loads, during erection, maintenance and repair or forces due to creep,
shrinkage, or settlement.
For the design of the individual structural components load combinations in accordance with the relevant design standards shall be considered.
All loadings considered in the design shall be justified with supporting details.
1.4.3
Tolerances
The following tolerances for buildings and structures are binding:

For dimensional tolerances of structures BS ISO 1803: 1997, DIN 18 201, DIN 18 202, and DIN 18 203
are binding.
The maximum allowed settlement under buildings shall not exceed 2.5 cm. In case of soil improvements or deep foundations works, specified allowable settlements under the relevant sections shall
be followed.
For equipment foundations OEM requirements shall be followed.
For deflection of structural steel members the following shall be applied:
Type of members
Girder-beams supporting floors, walkways

Pipe rack beams
Crane-track or trolley beams (exc. impact)
Monorail girders (crane loads need not be combined with wind or seismic loads)
Wall stanchions and girders
Roof girders or purlins
DL : dead loads - all permanent loads;
Deflection
Simple / continuous beam
1/300 L
1/300 L
1/1000 L
1/500 L
1/300 L
1/300 L
LL : live loads
Remarks
Cantilever
beam
1/250 L
1/200 L
1/350 L
DL + LL + W
DL + LL + W
DL + LL
Only for wind

force
DL + LL + W
W : wind load

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1.4.4
Special Requirements for Materials To Avoid Corrosion Problems Reinforced

Concrete
1.4.4.1 General
Due to very severe climatic conditions in the project area, special measures are necessary to protect
the different materials from corrosion. In this context the following materials need protection
measures:
1.4.4.2 Reinforced Concrete

The following special design aspects have to be considered by the Contractor:
Top surfaces of all indoor and outdoor equipment foundations and slabs where surface water/fuels/chemicals might accumulate (due to leakages or similar), shall be provided with a slope. towards drain channels/drain pits.
For the same reason as above, the exposed concrete edges shall be chamfered.
In order to control the size and mitigate the occurrence of cracks and to ensure concrete durability,
the Contractor shall implement the following design requirements:
Use smaller reinforcing bars well distributed over the zone of maximum concrete tension.
Use Portland cement conforming to the requirements of ASTM C150, Type II.
Using blended cements or adding materials such as pulverised fuel ash, ground granulated blast furnace slag or silica fume in order to increase the density of the concrete mix.
Use very dense, low water/cement ratio (not exceeding 0.40) concrete.
Use synthetic fibres to minimize surface shrinkage cracks (Synthetic fibres shall not be used in reinforced concrete structure).
Provide foundation tanking and/or surface coating.
Provide strict measures for concrete curing to prevent plastic shrinkage and thermal gradients resulting from early age heat of hydration of fresh concrete.
Protect inserts, anchor bolts and all steel items embedded in the concrete from corrosion.
Prevent the usage of steel profiles in small concrete sections.
Identify clearly the locations of the construction joints as well as their surface preparation in the drawings.
Incorporate other factors to increase concrete durability in concrete specifications, such as special
measures for concrete protection in the Gulf region, especially for hot weather concreting etc.

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Give special consideration for the protection of concrete surfaces subject to high temperatures during
plant operations.
Water retaining structures as tanks, manholes, pits including cable trenches shall be designed to BS
8007/BS EN 1992-3, where crack widths are not to exceed 0.2 mm.
Depending on the place of use, the special corrosion protection measures for reinforced concrete shall
be as follows:
Buried concrete or concrete within the groundwater capillary zone:
Minimum concrete cover 75 mm
Measures as outlined above and use of microsilica
Outside protection by tanking membranes and protection boards, with membranes extending 15 cm above ground level.
Concrete above ground
Minimum concrete cover 50 mm.
Measures as outlined above and use of microsilica
Outside protection and coatings as specified in Tender Document Volume II, Part G05.5 Corrosion Protection and Painting
Concrete exposed to chemicals:
same measures as for item (2) above
In addition finished surface to be protected with appropriate finishes as acid/alkali resistant

tiles. GRP lining (neutralization pit, tanks) as applicable. Coating as specified within Tender
Document Volume II, Part G05.5 Corrosion Protection and Painting.
1.4.5
Special Requirements for Materials to Avoid Corrosion Problems Steel

Structures
The following steel structures shall be hot dip galvanized and painted according to Tender Document
Volume II, Part G05.5 Corrosion Protection and Painting:
Steel structures and structural members inside buildings /open air arrangement
Structures with chemical exposure
All secondary steels (pipe racks, platforms, stairs, railings, ladders) and equipment supports/skids
All bolts /nuts (if not of stainless steel). Embedded parts of bolts/anchors inside concrete need
not to be painted.
All anchor bolt s and inserts shall have a concrete cover of at least 100 mm.

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The Contractor shall provide all technical information and a complete list of all parts to be galvanized
for the Employer/Engineers approval.
Galvanizing shall be carried out in accordance with BS 729/ BSEN 10143, and shall be smooth, continuous and free from flux stains. The minimum average coating weight of galvanising shall be as follows,
if not higher values are specified elsewhere,
Thickness of steel articles
Minimum average coating weight
5 mm thick and over
610 g/m
Under 5 mm but not less than 2 mm
460 g/m
Under 2 mm but not less than 1 mm
335 g/m
Note:
610 g/m is equal to a thickness of 86 m.
Small areas of galvanised coating damaged by welding, cutting, or during transport shall be repaired
by applying at least two coats of zinc-rich paint.
1.5
Materials (Quality, Delivery, Storage, Handling)
1.5.1
General
Only approved construction materials shall be used. Material that has not been approved by Employer/Engineer must be removed and disposed of at the Contractors own expense. For this purpose,
Contractor shall establish at site a quality control procedure for material delivery and notify Employer/Engineer for inspections and witnessing of sampling for testing. All sampling works shall be
done by the third party specialist/technician. All tests reports along with analysing of results and comparison with the specified/standards criteria shall be submitted as soon as possible results are available.
1.5.2
New /Unused Materials
Only new /unused materials shall be used and no recycled material is allowed. All materials must be
proofed and tested by an independent approved third party firm accredited by DM with design certification from the manufacturer. All proposed materials intended to be used for construction shall have
a record of previous approvals (mainly from local authorities) and usage in similar projects and under
the same environmental and harsh weather conditions. Services of testing shall be extended to earth
works/soil properties, concrete, steel and other materials whenever called by Employer/Engineer on
the account of the Contractor.
For testing of these works, sampling, handling, transport to the laboratory, reporting and analysing of
the test results shall be by Third Party specialized laboratories. The reporting and analyzing of the test
results shall be submitted to the Employer/Engineer.

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1.5.3
NA
1.5.4
Samples
The Contractor shall provide samples of all materials, embedded parts and installations, for the Employer/Engineers review before start of construction. Three samples of each main construction material shall be submitted for Employer/Engineer selection.
All approved samples shall be collected and stored in a sample room and all approvals shall be consecutively recorded.
1.5.5
Supplier/ Material Approval Procedure
The Contractor shall supply, as far as is practical, the following information:

On supplier or source a review of previous performance in supplying to similar specifications, evidence
that he can legally supply to UAE, capacity of plant, other ongoing commitments, details of main items
of plant and key personnel, independent references (if any and preferably unsolicited), test reports on
similar products (again preferably independent).
On materials or products a copy of drawings, design calculations, supplementary specifications, and
previous test results, inspection, taking samples and tests according to the specification. All that is
necessary and sufficient information to demonstrate conformance with this specification.
Approvals previously granted for any materials etc. shall be withdrawn if they are not properly transported, handled or stored and otherwise protected against weather or contaminants, which may adversely affect their properties. The Contractor has the option of removing such materials or having
them retested for approval.

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Site Installation and Demobilisation
2.1
Refer to Tender Document Volume I, Part G03 General Project Requirements. Due to the limited
space on the plot area, it is not allowed to use it for long term storage of any equipment and/or material.
Areas allocated by Employer, for the site installations shall be utilized in an optimized manner for offices workshops and stores. All site offices shall be built as multi storey buildings.
The Contractor, if requiring additional area, shall look for sufficient lay down areas, storage space and
facilities, labour camps, parking places off site. The Contractor shall be responsible for obtaining all No
Objection Certificates (NOC) of various authorities without additional cost borne by the Employer
All construction areas, storage areas and any other temporary site installations shall be surrounded by
temporary fences as per local authorities requirements. All underground services crossing the access
roads to the construction areas shall be protected by Contractor by means and structures approved by
Employer/Engineer.
2.2
Execution (Assembling, Installation)
All works for site installation must be executed in accordance with latest Health, Safety and Environmental rules (HSE)
Basic cleaning includes all floors, walls, ceilings, built-in fittings and equipment, including the furnishings. The basic cleaning operation must result in a degree of cleanness which permits the fully
equipped buildings and rooms and associated outdoor installations and secured surfaces to be taken
over without complaint. The Contractor shall be responsible that all cleaned areas and facilities will be
conserved at a complete clean stage till to the final handing over to the Employer.

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Site Supervision/Survey/Investigations
3.1
Site Supervision:
The Contractor shall establish at Site a team of experienced civil engineers dedicated for review and
checking of civil design and drawings only. Team leader shall be an Engineer from home office organisation of the Contractor with minimum 10 years experience in the field and shall be responsible for
the correctness of design and its conformity with the specifications. Documents and drawings shall be
forwarded to the Employer/Engineer for his approval only after being reviewed and signed by the assigned team leader. The same team shall be also capable to make minor changes and corrections in
design drawings during the construction stage.
Contractor shall establish another team of experienced civil engineers dedicated for checking of site
works of civil sub-contractor. As above, team leader shall be an Engineer from home office organisation
of the Contractor with minimum 10 years experience in the field and shall be responsible for the conformity of the sub-contractors works with the design and the specifications and for the quality of
workmanship. The Employer/Engineer shall be called for inspection only after the assigned team
leader confirms his checking by signing in the inspection sheets.
Prior to release for pouring of concrete for floors, walls and roof of buildings, structures and foundations at site, each sub-contractor is responsible for checking of formwork and reinforcement as well as
his latest requirement concerning the location/projection of anchor bolts and embedded items, the
location and size of equipment pads and foundations, the location and slope of piping, conduits, cables,
wiring and accessories, location and size of floor, wall and roof penetrations. After checking for correctness of the concerned disciplinary Contractor shall sign a "Free for Casting Certificate" which permits the Civil sub-contractor to proceed with casting of concrete and/or constructing after release of
the same by the Employer/Engineer.
The Contractor shall submit individual inspection sheets to the Employer/Engineer 24 hours prior to
the commencement of the works such as excavation, backfilling, concreting and structural steel erection etc., Works shall commence only after Employer/Engineers approval the inspection sheet. Employer/Engineers approval shall, however, not relieve the Contractor of any of his obligations under
this Contract. Form of the inspection sheet shall be proposed by the Contractor and approved by the
Employer/Engineer.
It is to be noted that should the Contractor repeatedly fail to notify or inform the Employer/Engineer
of inspections, sampling or testing (if any) then the Employer/Engineer may carry out independent
checks without informing the Contractor and reject parts of the works should the results of such inspection or testing merit. As far as is practicable the Employer/Engineer shall have free access to the
site, fabrication areas and suppliers work at all times without notice. Should he discover unsatisfactory
work then he will invite a formal joint inspection. Either after such an inspection or if the Contractor
declines the invitation the Employer/Engineer shall issue instructions with regard to the faults and
their reparation.
The Employer/Engineer may select the sampling point at no cost. The Employer/Engineer may instruct
tests at no cost provided either the overall frequency governed by the specification is not exceeded
and the notification given to the Contractor is equal to that currently being provided by the Contractor

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for his normal testing in formality and warning, or the Employer/Engineer has due cause to suspect a
change in the quality, such concern having been advised to the Contractor.
The Employer/Engineer may instruct sampling, testing or both which satisfy only some or none of the
above criteria.
3.2
Survey and Investigations
To enable the Contractor to carry out his survey and construction work, he will be furnished by the
Employer with the bench marks showing their description, number, co-ordinates and levels to an extent necessary for the work. These information are preliminary and the Contractor is responsible to
check, verify and correct, if required, these data before starting his work and he must forward a written
notification concerning the discrepancies to the Employer/Engineer and obtain his approval.
All surveys required for construction of the works shall be performed by the Contractor as construction
work proceeds. Survey points distributed at different locations established by contractor shall be durable and suitably protected to avoid any damage through out the construction period.
Levelling bolts according to DIN 18708 shall be installed by contractor for the RCC foundations and
structures immediately after construction and protected from damages till handing over.
In all buildings and major foundations at least 4 levelling bolts shall be installed at 1.00 m above floor
surface.
The position and the total number of surveying points shall be finally decided by the Employer/Engineer in co-operation with the Contractor, on the basis of the settlement report.
Measurements of all levelling bolts are to be executed:
immediately after setting of the bolt
prior to the erection of mechanical equipment
several times during the erection period of the mechanical equipment
after completion of the buildings/structures and erection of all equipment
Once before the plant is handed over to the Employer.
All reports shall be submitted on regular basis as agreed by EMPLOYER/ENGINEER.

The Contractor shall establish and mark one reference permanent survey point with co-ordinates and
elevation at each floor level (preferable at column face) within all buildings and structures. This reference survey point shall be used by the electrical/ mechanical Contractor for the equipment erection
work.

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Dewatering During Construction
This section applies to the methods and techniques of ground water control. All costs for ground water
control for keeping the construction pits and areas at least 500 mm below formation level dry shall be
included in the lump sum.
The method and technique shall be based on the British Standard BS.8004 or any equivalent agreed
with the Employer/Engineer. NOC shall be obtained from Dubai Municipality prior to installation of
dewatering system.
The scope of supply includes the installation of all equipment, plants, pipes, machinery and its removal
after completion including operation and maintenance of the equipment during the construction period. All equipment, instruments, machinery, tools, pipelines, required for execution of the water control shall be in good repair and shall be kept in good working condition throughout the operation period.
Where necessary, cofferdams, sheet piles, pump sumps, equipment and channels, troughs, inlet gutters, pipes and any other works required for the water control and discharge shall be part of the scope
of supply. The dewatering system shall be designed and installed in such a way that alteration and
extensions can be made at any time throughout the operating time, if necessary. Reserve units shall
be kept ready for service when failure of any of the installed units occurs.
The Contractor shall submit to the Employer/Engineer, the detailed method of the envisaged pumping
system for dewatering, the pump capacity and the standby reserve units.
The Contractor must ensure that any dewatering works will not cause any interference to his own work
and to those of other Contractors working elsewhere on site or at structures under construction or
existing structures and facilities. Any damage occurring during the above mentioned period shall then
be made good by the Contractor at his own expense.
Routing and location of water discharge lines shall be submitted to the relevant authorities and to the
Employer/Engineers review. The disposal of water shall be in accordance to the local environmental
laws and regulations. If applicable according to the local laws and regulations the pumped water has
to be treated accordingly before disposal.
The Contractor shall maintain ready-for-service and regularly clean all dewatering equipment and accessories and shall keep all access clear so that they can safely be used without risk of accident. Any
requirements made by the Employer/Engineer in this matter shall be carried out immediately.
4.1
QA/QC
The Contractor shall keep records of all data of importance occurring during operation of the water
control system. The records shall be submitted to the Employer/Engineer for information and checking
every working day. For that purpose, the lowering of the water table shall be controlled by piezometers. The numbers and position of them shall be submitted to the Employer/Engineer's for approval.
The Contractor shall provide and maintain these piezometers at his own expenses during the dewatering works or as long as the Employer/Engineer requires it.

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Pump operations shall not be stopped nor pipes, channels and equipment for dewatering and water
control removed or altered in any way, except with the express permission of the Employer/Engineer.
The Employer/Engineer will stipulate the time of removal. Until then, the pumps and water drainage
facilities shall be kept in proper working order without extra payment being granted.

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Site Clearance and Earth Work
5.1
Site Clearance- General
The exiting ground level of the site area is about + 3, 00 m DMD and plot area is partially covered with
trees that shall be treated as per Tender Document Volume III, Part P20 Civil Works. Due to the high
ground water level the site area shall be backfilled up to a level of + 4.00 m DMD by selected fill material with properties specified here down and approved by Employer/Engineer. Elevated plant area shall
be coordinated with surrounding structures/facilities/services/roads and shall be well designed for
smooth transition at road connections. Soil embankments shall be protected against soil movement
by suitable stone pitching of size at least 200 mm laid on a well prepared and compacted surface and
above a 100 mm thick concrete blinding layer. Joints of stones shall be filled and grouted with blended
cement and additives that will guarantee a durable construction with minimum maintenance. The final
finished ground level of buildings shall be +4.20 m DMD.
This work consists of clearing, grubbing and stripping the area of the work of stumps, bushes, roots,
down timber, rotten wood, rubbish, debris, humus, swamp material and any other vegetation or unacceptable materials as ordered by the Employer/Engineer.
Disposal of excess soil and unusable waste materials shall be the responsibility of the Contractor. The
Contractor shall transport the materials to a suitable dumping area and obtain the necessary approval
from the municipal authorities at his own expense. Stacking of all materials shall follow the Green
Buildings Regulations regarding segregation
Burning and blowing off of any material and use of explosives is not permitted.
Prior to start clearing or filing works, contractor shall locate any existing underground services and
protect or relocate as per Employer/Engineer approval at his own cost.
5.2
Earth Works, Completeness
The Contractor shall satisfy himself as to the ground conditions on the site including the nature of the
strata to be excavated, obstructions, possibilities of flooding and such like and shall allow for all provisions necessary to carry out the work in the most suitable manner when submitting his tender.
Generally all buildings and structures must be founded on bearing strata which means that all excavation work for foundations shall meet the requirements of structural analysis based on the results obtained from the soil investigation and of the available information and instruction given in writing by
the Employer/Engineer.
Excavation shall be done to the required dimensions including required working spaces and shall be
finished according to the specified lines and slopes. All necessary precautions shall be taken to cause
the minimum possible alteration or disturbance to the material lying under and adjacent to the excavation final lines.

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5.3
The fill materials used are to be examined and approved. Excavated materials can be used if they fulfil
the requirements.
5.3.1
Select Fill
Select fill shall have the following properties:

Well graded (uniformity index not less than 5), non-cohesive and nearly silt free (silt content not
greater than 5%; up to 10% tolerated, except below footings of structures) and plasticity index not
exceeding 6, liquid limit not exceeding 40 %, salt free (content less than 3%), soils free of organic matter (limit 2%). Decomposing or compressible materials shall not be used.
All material shall be of such nature and character that it can be compacted to the specified densities
in a reasonable length of time. It shall be free of highly plastic clays, of all materials subject to decay,
decomposition or dissolution, and of cinders or other materials which will corrode piping or other
metal.
The intention is to use select fill below structures, roads, parking areas.
5.3.2
Ordinary Fill
Ordinary fill shall have the following properties:

Natural inorganic soils: salt content not greater than 3%, organic matter less than 3%. For other properties see under 'Select fill'.
The intention is to use ordinary fill for non-built areas.
5.3.3
Special fill
Special fill material shall be gravel or crushed rock (for other properties see under 'Select fill').
The intention is to use special fill e.g. as sub-base material for tanks and roads.
5.4
The works shall be excavated either by hand or by use of excavating plant and tools acceptable to the
Employer/Engineer. Method statement for earth works shall be submitted for approval by Employer/Engineer.
5.4.1
Safety Precaution
The Contractor shall be responsible for all necessary safety measures.

Proper strutting, sheeting and bracing, including re-arrangement of the installations when necessary,
stabilization and protection of slopes by hessian and cement, methods of excavation to reduce risks of
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slides shall be to the Contractor's debit. The additional moving of soil resulting from such damages will
not be paid for.
5.4.2
Stockpiles and Disposal
The construction and lay down areas are limited. Excavated material from the Works selected by the
Employer/Engineer for re-use shall be placed immediately in its final position, if possible, or otherwise
may be stockpiled or deposited on Site or carted away as directed by the Employer/Engineer. It is the
responsibility of the Contractor to determine the location of an off-site disposal area. Stockpiling is
accepted for short periods only and in any case it shall not obstruct the construction and progress of
site works.
The Contractor shall not have the right either to additional payment or to claim because of work involved in stockpiling materials, re-use of for carting to the waste disposal areas. Necessary approvals
shall be obtained from concerned authorities for waste disposal areas.
5.4.3
Preparation of Foundations
For all types of foundations and immediately after excavation the formation level of foundations shall
compacted up to 98% (degree of compaction) , and then protected by means of a lean concrete layer,
7.5 cm in thickness over a layer of plastic sheet. No concrete is to be poured until formation level is
inspected and agreed by the Employer/Engineer. Plate load test shall be conducted at site under areas
agreed by Employer/Engineer in order to verify the parameters considered in design.
For all foundation works, formation level shall be at least 1.0m below the finished ground level.
5.4.4
Backfilling
Foundations and structures shall be backfilled as shown on the drawings with agreed material compacted in layers by suitable equipment until optimum stability has been obtained to the satisfaction of
the Employer/Engineer. Compacting shall be carried out with special care by means of pneumatic or
mechanical rollers or other compactors of a type previously agreed by the Employer/Engineer.
Density requirements shall be as follows by tests per modified AASHTOT-180 Method D, at optimum
moisture content
Under buildings and structure foundations and slabs
Under roadways and parking areas
Embankment - 95%
- 98%
- 98%
Backfilling of foundation work with agreed materials shall be carried out only after foundations have
been inspected by the Employer/Engineer.

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5.4.5
Soil Replacement
The material to be used for replacement of soil shall not contain soluble or swelling components such
as clays, or organic matters. Sand gravel mixtures of agreed grain size distribution shall be used in
exchange.
The fill material shall be placed in horizontal layers of no more than 25 cm thickness. The fill moisture
content shall be controlled and adjusted in order to achieve a maximum of compaction. Fresh water
shall be used for watering of soils. The foregoing shall be confirmed by Tests mentioned in Tender
Document Volume III, Part G05.6 Inspection and Testing. One Modified AASHTO or Proctor and three
(3) density tests shall be made at every second fill layer prior to continuation of filling work. The testing
location will be indicated by the Employer/Engineer. The results of the tests shall be made available to
the Employer/Engineer within 24 hours of the tests. Filling work may be continued in case all tests
performed show satisfactory results.
5.4.6
Pipe Bed Preparation
Pipe beds shall be constructed to guarantee the uniform transmission of loads. The bearing section for
supported profiles shall cover at least an arc of 90.
Pipes shall be bedded in an earth foundation of uniform density and carefully shaped by means of a
template supported at the desired grade, to fit the lower part of the pipe exterior.
Where a firm foundation is not possible at the grade established due to soft, spongy or other unstable
soil, all such unstable soil under the pipe and for a width of at least one diameter on each side of the
pipe shall be removed and replaced with suitable selected materials as agreed by the Employer/Engineer, properly compacted to provide adequate support for the pipe.
5.4.7
Protection of Existing Utilities and Services
During construction the Contractor shall provide all protection for existing utilities and services as may
be required by his construction operations. Permanent protection of certain items shall be as included
under other clauses or as instructed by the Employer/Engineer.
In addition to the requirements as specified, herein the Contractor shall comply with the following
requirements.
Use all necessary precautionary and protective measures required to maintain existing utilities, services and appurtenances that must be kept in operation. In particular the Contractor shall take adequate measures to prevent undermining of utilities and services presently in services.
Protect existing or new utilities and services where required by the Contractors operations and/or as
directed by the Employer/Engineer. The Contractor shall be responsible for bracing and supporting
utilities and services to prevent settlement, displacement or damage.

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5.4.8
Deep Vibratory Techniques
Loose or soft soils in the natural or existing stage unsuitable for foundation purposes can be improved
by deep vibratory techniques in order o maintain the settlement of structures within the allowable
limits. The technique by vibro compaction or vibro displacement, material and design/details of the
deep vibration are subjected to Employer/Engineer approval. All works shall be executed by an approved specialist in this field of works. Contractor is responsible to prove that those works does not
affect the operating power plant in any aspect.
By any approved technique, all layers between foundation level and bearing soil are to be compacted
to a relative density of at least 80% and prepared for an admissible soil pressure of at least 250 kN/m2.
And settlement of structure/foundation is limited to 1.5 cm.
The final foundation level shall be covered with at least 50 cm crushed stone or gravel fill and compacted to 95% relative density with a 10 ton vibrating roller (at least two layers performing 6 passes);
All water used in construction and soil improvement shall be fresh water.
5.4.9
Dust Control
The Contractor shall use all means necessary to control dust on roads, construction areas and borrow
pits. Surfaces shall be regularly on daily basis and when required, watered to prevent dust becoming a
nuisance for the public and have impact on the nearby installations and services or interfering with the
proper execution of the works. Waste oil is not permitted for the use as dust control. Temporary roads
and access ways may be covered with suitable gatch materials to reduce the development of dust.
Sand and dust (especially cement dust) shall be contained with in the construction site. Method statement for dust control shall be approved by Employer/Engineer.
5.5
QA/QC, Test and properties
5.5.1
General
The Control of working and tests operations shall be carried out by the Contractor in the presence of
the Employer or Engineer.
The Contractor shall prepare sheets for statistical analysis of the field and laboratory tests, and shall
submit the sheets to the Employer/Engineer for approval. Controlling will consist of field and laboratory tests, such as:
One (1) test analyzing the chemical ingredients of the water used for performance of the work
and the soil.
One (1) test for bearing capacity of soil for static load as per ASTM D 1194 - 57.
Three (3) tests for density of soil in place of sandcone method for each second layer of "Backfilling
and/or replacement of material and/or roadwork" are required as per ASTM D 1556 - 64.

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All tests shall be recorded in forms acceptable to the Employer/Engineer.
Tests shall be performed for each 500m3 of fill but not less than once per shift.
5.5.2
Quality Assurance for Vibro Techniques
Before starting the compaction works, the Contractor has to prove by tests whether he is able to improve the underground to the above requirements. The test program and vibro pattern is to be proposed by the Contractor and to be agreed by the Employer/Engineer, and shall contain a trial compaction, dutch cone tests (before and after the treatment) and big scale load tests comprising at least 4
compaction points covered by a concrete footing.
By the vibro compaction or vibro replacement, the soil is improved to meet the following Dutch cone
resistance requirements below the foundation level (in addition to other requirements):
from 0 to 3 metres:
cone resistance increasing linearly to 10 MN/m2
from 3 to 5 metres:
10 MN/m2
from 5 to 7 metres:
15 MN/m2
beyond 7:
20 MN/m2
The resistance for the first 3 m shall be 10 MN/m2, when the tests are done from a level more than 2
m above the foundation level. The results are judged to be successful if not more than 10% of the
measured values are below the above requirements. The tests will be performed in the most unfavourable location of a probe group. The number of sounding tests shall be at least 5 for one structure.
Big scale plate load tests shall be performed, for quality control purposes, at least two for each structure . These tests shall cover an area of 4 compaction points/stone columns in addition to the spacing
(in both directions) and shall be loaded to twice the permissible soil pressure.
All test results shall be compiled in test reports, where values obtained are compared with requested
values (in diagrams as far as possible, Es- values derived via settlement calculation from test results).
A method statement and quality control program shall be prepared by the Contractor and agreed by
the Employer/Engineer prior to start of vibro works containing at least the above requirements and
information about the following:
Description of large scale load test including load steps/waiting time
Data recording of probe number and depth, date and time of execution, installation time for every
probe, gravel consumption (if applicable), power consumption versus time or depth (automatically
recorded) etc.

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Piling Works
These specifications cover the requirements for the materials, the installation and the realization of
bored cast-in-place concrete piles and driven cast in place piles with grouting at the base. The scope
shall include the preparatory works for piling, design, construction works, testing, pile head cutting,
pile head treatment (waterproofing, grouting), cleaning, etc.
6.1
Documents to Be Submitted
The following documents shall be submitted by the Contractor to the Employer/Engineer in due time
and are to be approved before starting the piling works:
Design calculations of the proposed type of piles and detailed drawings including the typical reinforcing
details.
Design of the concrete mix as per Clause 7 specified herein.
Method statement for preparation, construction and testing.
Detailed description of the plant and equipment along with the pre-qualifications of the piling works
subcontractor.
Piles record book and concrete control record.
6.2
Design Criteria, Arrangement Drawings
The piling works and design shall be in accordance with the latest editions of internationally accepted
standards. Copies of codes and standards used for design and construction shall be furnished by contractor if requested by Employer/Engineer.
Two (2) types of piles foundation can be proposed and quoted by the Contractor: cast-in place driven
piles or cast-in-place bored piles. Grouting of the rock below the piles shall be considered if dictated
by soil conditions. The pile bases shall be embedded in the rock level, determined by the soil investigations made at the beginning of the works by the Contractor. The net vertical pile capacity computed
from the soil investigation report is used to determine the maximum test load in case of piles testing.
The net compressive stress within concrete shall not exceed 5 MPa. The net tensile stress within steel
reinforcement shall not exceed the allowable values furnished in the standards and norms.
6.2.1
Bored Cast-In-Place Piles and Driven Piles
Bored cast in place piles are drilled up to the depth indicated by the pile drawing submitted by the
Contractor and agreed by the Employer/Engineer. For each pile, the Contractor draws up the geotechnical profile of the drilling with description of the strata and samples taken for each stratum as mentioned in the piling record item of these specifications. A representative sample from each stratum will
be kept in tight packing until the end of the works.
A suitable type of drilling equipment shall be provided in order to penetrate obstacles (e.g. boulders)
which may be met during the execution of the piles.
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Generally drilling operations shall be carried out in such a way as to avoid any disturbance of the soil.
A temporary casing shall be installed to the full depth of the borehole (except in stable rocks). The
bottom of the casing shall always be kept sufficiently below the excavated borehole bottom, in order
to prevent inflow or loosening of the adjacent soil.
Just before reinforcing and start of concreting the pile foot is to be cleaned out so that no disturbed,
loose or weak soil remains below the pile tip.
For driven cast in place piles, the Contractor shall provide to the Employer/Engineer all data proving
the suitability, efficiency and energy of the driving equipment.
Comprehensive details and method statements for construction shall be submitted by Contractor for
Employer/Engineer approval. Anchorage in the Rock
When different top levels of the rock are encountered during the pile borings, the anchorage levels
will be adopted and submitted for review by the Employer/Engineer but the minimum embedment
shall not be less than 3 times the pile diameter.
When the bedrock is reached, the steel casing has to be pushed as far as possible into it, in order to
avoid penetration of sediments by any possible space between the rock and the bit of the steel casing.
6.3
6.3.1
Steel Reinforcement and Concrete
The piles shall be longitudinally reinforced on the whole length with high steel yield epoxy coated bars.
The minimum ratio of longitudinal bars is 0.8% of the pile cross section, with a minimum of 6 bars not
less than 12 mm in diameter. The minimum spacing between longitudinal bars is 15 cm (DIN 1045).
Helical binding shall be used with a minimum diameter of 10 mm and a maximum pitch of 15 cm.
Reinforcing cage shall be stable and bars properly tied with the helical stirrup at all joints with plastic
coated wires. It shall be perfectly centred within the borehole by the aid of concrete spacers distributed every 1000 mm centres along the vertical bars and has same properties as for the pile. The
concrete cover to reinforcement shall be not less than 75 mm and not more than 100 mm. The reinforcement cage is put into the hole in only one operation. The cage must remain stable during concreting and removal of the temporary casing. The handling of the cage during loading, unloading and
installation within the holes has to be made with care in order to reduce the deformation and to avoid
the breaking of the binding wires. Cages shall be held firmly in position by the aid of rigid hangers.
Proprietary PVC pipes shall be used to protect part of main bars that will be anchored inside the foundations/pile caps. Connections for main rebar splicing area shall be properly design to avoid settlement
during concrete pouring operation.
Concrete mix design for piling works shall be submitted for review by the Employer/Engineer.
The concrete shall be as per Clause 7. The water/cement ratio shall not exceed 0.40.

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6.4
6.4.1
Program
The program of piling work is to be submitted for approval by Employer/Engineer four weeks before
the start of the piling works. Sequence of piling shall be stated including adequate notice of his intention to work outside normal hours and at weekends. Daily reports shall be submitted showing the
actual accumulated progress and the plan for next day.
6.4.2
Qualification
The piles installation shall be undertaken using proven techniques and equipment and shall be implemented by specialist personnel who have extensive experience in carrying out such work. The Contractor shall provide qualified personnel i.e. a foreman for every piling crew, who shall always be present
during the works, as well as a professional engineer, well experienced in piling works, for supervision.
6.4.3
Staking-Out Tolerances
The maximum allowed deviation of the piles centre from the theoretical location shown on the setting
out drawing is 50 mm in any direction. The maximum permitted deviation of the completed pile from
the vertical is 20 mm per meter (2.0%). Contractor shall establish the reference bench marks, grids and
coordinates which shall be used for inspection and setting of piles.
6.4.4
Cut-off
The piles are to be concreted up to a minimum of 60 cm above the cut-off level.

The cut-off must eliminate all polluted or poor characteristics concrete at the top of the pile and should
be carried 50 mm into sound concrete. When this sound concrete is found below the cut-off level, the
Contractor must realize, at his own expenses, a new concreting up to the cut-off level with a full connection to the pile. Any repair must be agreed by the Employer/Engineer. Prior to proceed with
raft/pile cap foundations, pile head shall be wrapped with an approved swelling unit water bar, water
proofing membrane and grouted.
Rejected piles due to quality of concrete, or non compliance with design criteria shall be replaced by
the contractor on his own cost.
6.4.5
Working Platform
The areas where piling operations are to be carried out is to be levelled and kept clear of water to
provide a dry stable working platform for the plant and equipment operation which shall be 1 to 1.5
metres above the designed cut off level.
After completion of the piling works the project site is to be cleaned and all excavated material due to
these works is to be removed by the Contractor.

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6.4.6
Concreting
Before starting the concreting, the bottom of the hole has to be cleaned. All loose or disturbed soil will
be removed from the base of the hole. This operation is to be executed immediately before starting
the concreting. It means after the introduction of the steel reinforcement cage and not only at the end
of the drilling.
All concrete is to be placed by tremie pipe and concrete pump; the starting of the concreting by this
method has to be particularly well executed. The good quality of concrete at the base of the pile is of
main concern with this operation. Concrete operation shall stop only after visually seeing a good quality of fresh concrete at platform level.
After concreting of each pile, the concrete volume will be checked in relation with the theoretical borehole volume; for this purpose, a concrete-curve is drawn up for each pile, truck by truck. A complete
concrete curve is established from the measurements of concrete consumption every meter on the
length of the pile for 1 pile each 50 piles. The concrete-curves (truck by truck and meter by meter)
have to be daily provided to the Employer/Engineer and joined to the piling record.
If the concrete consumption is not normal (under-volumes or more than 30% of over-volumes), special
procedures will be taken by the Contractor in agreement with the Employer/Engineer.
The length of the tremie pipe is equal to the length of the pile. Before concreting, the pipe will reach
the bottom of the hole and is then raised in 15 cm steps. The pipe must never be located less than 1.5
meter below the level of workable concrete within the pipe.
At all times, a sufficient quantity of workable concrete shall be maintained within the pipe to ensure
that the pressure from it exceeds that of the water.
During the extraction, the base of temporary casing must be located at least 1 meter below the level
of fresh concrete and workable concrete shall be added to cover the drop due to casing removal. Temporary casing shall be removed by vibration, not disturbing the consistency of the concrete.
For each group of 5 piles, 6 representative cube samples will at least be taken, 3 will be tested after 28
days, and the others will be stored for other tests to be specified by the Employer/Engineer such as
durability and chloride/sulphate contents of supplied concrete.
All costs relative to these control tests are under the scope of the Contractor
6.5
QA/QC
6.5.1
Piling Record
For each pile, a piling record book giving the main checked values during execution shall be drawn up
and updated by the Contractor with all the work hazards and incidents. That record book shall be submitted daily for review by the Employer/Engineer as the execution proceeds.
This record book shall include for each pile details on:

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Location, reference number (corresponding to the number fixed on the drawing), type and diameter of the pile;
Length of the temporary casing;
Date and hour of start and end of each operation drilling, reinforcement setting, concreting;
Level from which the pile is bored or driven (platform level);
Level at the pile base;
Top level of the concreted pile before the cut-off operation;
Nature and description of the encountered soils;
Poured concrete volume and theoretical volume (measured concrete curves);
Water level within the hole before concreting;
Records shall be submitted in duplicate to the Employer/Engineer every following working day
until 9 a.m.
The Contractor shall submit for review by the Employer/Engineer a proposal of piling record and concrete quality control sheets including all the details mentioned above.
6.5.2
Test Piles, Static Loading Tests
The Contractor shall execute static loading tests for preliminary piles in the following quantity:
up to 10 piles:
1 tests of each type (tension, compression and diameter),
up to 30 piles:
more than 30 piles:
and for working piles, it shall be 2% of the total piles (each type) executed at Site but not less than
3 piles.
The pile(s) to be tested shall be agreed by the Employer/Engineer. The procedure to be followed is
provided by ASTM D 1143 or by BS 8004 art. 7.5.5 and local authorities requirements.
The maximum test load shall be 2.5 times the working load for preliminary piles and 1.5 times the
working load for work piles. Total settlement measured from the start time of loading up to the end of
loading (all increments and cycles of loading and off loading) shall not exceed 7 mm for preliminary
piles and 5 mm for working piles. (Integrity tests are to be performed on 100% of the piles.
The loading materials and equipment, the measurement devices and procedures have to be submitted
for the Employer/Engineer's approval by the Contractor.

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All tests will be carried out only under the direction of an experienced and qualified supervisor familiar
with the test equipment and test procedure. The number of increments of load shall be at least four,
with a decreasing of load down to zero after each increment.
If tests prove unsuccessful, the Contractor shall propose all necessary adaptation to the foundations.
These proposals shall be submitted to the Employer/Engineer. All costs requested to perform the foundation adaptation shall be at the Contractor's expense. The Contractor is responsible of the resulting
time delay.
In addition to the above tests, further tests in accordance with the Dubai Municipality regulations (Dynamic and sonic testing) shall be conducted as required. The Contractor shall contact Dubai Municipality for determining what additional tests are required.

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Concrete Work
7.1
This specification covers the technical requirements of all concrete works (reinforced concrete, mass
concrete and precast concrete. The scope covers all temporary works as shuttering, scaffolding and
testing of all materials.
7.2
In general the specifications for concrete works are based on
American standards (ACI and ASTM) mainly ACI 305R, 318, 318R, British Standards (BS) mainly BS
8110 part 1 "Structural use of concrete",
the provisions of German Standards DIN, mainly DIN 1045, "Concrete and reinforced concrete
structures, design and construction,
EN 206-1 Concrete, specifications, properties, production and conformity and
the specification of the CIRIA Guide to construction of reinforced concrete in the Arabian Peninsula.
In order to protect the concrete against high concentrations of chlorides and sulphates, all measures
should be taken to achieve as dense a concrete as possible.
The concrete design and working drawings of main structures, and if required also of secondary structures, shall be submitted by the Contractor for approval by the Employer/Engineer.
7.3
Dimensional tolerances
The permissible tolerances must comply with the DIN 18201, DIN 18202, DIN 18203.
7.4
Concrete with Special Properties
7.4.1
General Requirements
The precondition for obtaining concrete with special properties is that it should be made with the
appropriate composition, that it is placed in such a way that segregation does not occur and further
that it is fully compacted and given appropriate curing.
All reinforced concrete must meet the durability requirements. The water-cement ratio must not exceed 0.40 and all mixes shall contain microsilica.

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Concrete additives approved by the Employer/Engineer shall be used to improve density, consistency,
workability, quality and strength of the concrete. Chemical admixtures manufacturer shall provide certified test reports from qualified independent laboratories showing actual test results indicating material that complies in all respects with the applicable specification.
Admixtures used in concrete shall conform to the appropriate specification and requirements as indicated below:
Air entraining admixtures shall conform to ASTM C 260.
Water-reducing and retarding admixtures shall conform to ASTM C 494. Accelerating admixturesshall not be used. Type F or Type G high range water reducers shall conform to ASTM C 1017
andshall be "Rheobuild 561" or Rheo-build 716" as manufactured by Master Builders or equal.
High-range water reducers shall be naphthalene-sulfonated polymer based material. No admixtures containing chlorides shall be used.
Chemical admixture suppliers shall provide certified test reports with each shipment indicatingcompliance with the appropriate specification. The test reports shall include the chloride content of the admixture, specific gravity and solids content.
Silica fume may be either a condensed form as manufactured by Master Builders, Microsilica Ltd.
or a slurry form F-100 as manufactured by ELKEM Chemicals or other approved products.
When microsilica is batched as a slurry, the liquid portion shall be included as part of the mix water.
Microsilica shall meet the following requirements:
SiO2 (min) % 90
SO3 (max) % 1.0
C (max) % 6.0
In order to avoid any problem, which may occur due to the improper use of microsilica, all the possible
problems related to the use of microsilica shall be coordinated with a specialist of microsilica supplier.
Mainly the following shall be coordinated:
Microsilica content shall be 8% by weight
Admixtures used in production of concrete shall be the same as used in establishing the required
concrete mix and shall be used in accordance with the manufacturers directions.
Concrete should be as stiff as possible, in order that there will be no concentration of cement
slurry or water in the top layer. The concrete should be kept moist for at least 7 days after placing.

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7.5
Finishing Of Concrete Surfaces
RCC columns, beams and slab soffits are to be fair faced without secondary finishes except coating.
Special attention shall be given for shuttering works in order to reduce board marks and loss of concrete slurry from the mix.
Floor slabs and foundations shall be treated and prepared in order to receive the subsequent finishing
or top layers works (tiles, cement screed, waterproofing, epoxy screed, etc.).
7.6
Bar-bending Schedules
The Contractor shall prepare bar bending schedules based on the detailed reinforcement drawings and
following the international standards for formats and details. These shall be presented to the Employer/Engineer for information at an early stage in the contract, certainly before finalization of his
order for reinforcement for that particular part of the work. .
Reinforcing steel used in reinforced concrete shall comply with the following standards:
British Standards:
BS 4449
"Hot rolled steel bars for the reinforcement of concrete"
BS 4482
"Hard drawn mild steel wire for the reinforcement of concrete"
BS 4483
"Steel fabric for the reinforcement of concrete"
BS 4461
"Cold worked steel bars for the reinforcement of concrete"
7.7
Crack Widths of reinforced Concrete Structures
All reinforced concrete structures shall be designed to BS 8110 where crack widths are not to exceed
0.3 mm, or BS EN 1992-1. Water retaining structures (including cable trenches, manholes, cable pits
and basements) shall be designed to BS 8007 or BS EN 1992-3, where crack widths are not to exceed
0.2mm,
7.8
7.8.1
Quality of Materials
All materials used for concrete and reinforced concrete structures shall be of the best quality, free
from defects likely to undermine the strength and duration of service of the works. The materials furnished must at least comply with the agreed standards, and with all requirements described in this
specification.

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7.8.2
Storage of Materials
All materials shall be stored and handled in a manner that will prevent contamination and/or deterioration. Deteriorated and/or contaminated material shall not be used for the concrete and shall be
removed from the site at the expense of the Contractor.
7.8.3
Cement
The cement used for concrete, reinforced concrete, mortar, grout and plaster works shall be Portland
Cement in accordance with ASTM standards type II. If the aggregate is determined to be potentially
reactive, the alkalis as (Na2O + 0.658 K2O) in the cement shall be 0.6 percent or less. Cement shall be
obtained from sources approved by Dubai Municipality.
7.8.3.1 Sampling and Testing Of Cement

All deliveries of cement to the concrete supplier shall be accompanied by a certified mill test report
and shall include all of the physical and chemical properties as required by tables 1, 2, 3 and 4 of ASTM
C150 for type II cement. Additional testing to verify the properties shall be done upon the request of
Employer/Engineer.
7.8.3.2 Delivery and Storage of Cement

All bagged cement used at site shall be stored in a weatherproof building having dense impervious
bituminous or concrete floors which shall be kept swept clean at all times. The storage arrangements
shall be fully completed and agreed by the Employer/Engineer before any cement is delivered to site.
Any partially set cement or contain hardened lumps shall be removed from site without delay.
7.8.4
Water
Water used for mixing and curing shall be potable and supplied from approved sources .
7.8.5
Aggregates
7.8.5.1 Material
The aggregates for concrete shall be crushed mountain rock subject to Employer/Engineers approval.
The aggregate (fine and coarse aggregates) shall be supplied from an established pit or quarry approved by Dubai Municipality. The aggregate source shall have a minimum five (5) years history of
satisfactory performance in structural concrete and consistency of supply.
Samples of the proposed aggregates for concrete mixes shall be collected and tested to confirm its
compliance with the specified properties:

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Test
ASTM C
29
ASTM C
88
ASTM C
117
ASTM C
131
ASTM C
136
ASTM C
142
ASTM P
214
ASTM C
289
ASTM C
127
ASTM C
128
Coarse Aggregate
(20 mm and 10 mm)
Unit weight
Soundness
5 Cycles
MgSO4
Clay, Silt,
Dust
Abrasion
No Limit
12 %
Gravel
Crushed Rock
1%
3%
30%
Fine Aggregate
5 mm and Dune Sand
No Limit
15%
3%
5%
30% (5 mm 0nly)
Gradation
NMS 20 mm shall have not more than

10 percent retained on 20 mm sieve
and not more than 5 percent passing
the 10 mm sieve, NMS - 10 mm shall
have not more than 10 percent retained on 10 mm sieve and not more
than 5 percent passing a 2.36 mm
sieve
NMS 5 mm shall be well

graded such that when
blended with dune sand the
fineness modulus shall be
between 2.6 and 3.0. Dune
sand may be used achieve
an acceptable gradation
Clay lumps
(Max.) 2 %
(Max.) 3 %
Deleterious
expansion
due to AlkaliSilica reaction
Potential reactivity
Chemical
method
0.10% @
16 days
0.10% @
16 days
Absorption
and specific
gravity
coarse aggregate
Absorption
and specific
gravity fine
aggregate
Specific gravity > 2.5 (SSD) Absorption

< 2.0
No limits applicable. Report the concentration of dissolved silica Sc and reduction in alkalinity Rc.
Specific gravity > 2.5 (SSD)

Absorption < 2.0
ASTM C
40
Organic impurities
Lighter than standard
ASTM C
87
Effect of organic impurities on

strength of
mortar
Relative strength 7 days

> 95 %

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Test
BS 812
Part 1
BS 812
BS 1377
Coarse Aggregate
(20 mm and 10 mm)
Elongation
< 25 %
index
Flakiness in< 25 %
dex
Section 105.1
Total sulfates < 0.4 %
Section
3.2
Test 9
(Crush all
material to
pass 2 m
sieve)
BS 812
Total chloride
as cl
Fine Aggregate
5 mm and Dune Sand
< 25 %
< 25 %
< 0.4 %
<0.03%
<0.06%
Testing is to be carried out at the following intervals:
Type
Grading
Specific Gravity
Magn Sulfate soundness
Clay Silt and dust content
Shape (Elongation and flakiness)
Los Angeles Abrasion
Moisture content
Drying shrinkage
Organic impurities
10% fines value for concrete
Coarse Agg
Daily
7 days
30 days
daily
3.5 days
Initial stage only
2 days
Initial only
30 days
7 days
Fine Agg
Daily
7 days
daily
Initial stage only
2 days
Initial only
30 days
-
Combined grading also on a daily basis.

In addition to above, aggregates shall have Petrographic examination in accordance with ASTM C 255
performed by a qualified concrete aggregate petrographer. This report shall address all items contained in ASTM C 295, section 15. This report shall be based on material produced and examined within
the previous six (6) months and shall be representative of the current production.
7.8.6
Reinforcement, Treatment and Coating of Reinforcement
All reinforcing bars, fabrics and steel embeddings used in substructures shall be from sources approved
by DM. Reinforcing bars for piling works and substructures shall be epoxy coated as per ASTM A775
and shall be used as described under piling works section .The average thickness of the coating shall
be 250 m . Samples shall be collected from material delivered to the site and tested.to Any non compliance of the epoxy coated bars with ASTM A775 shall be a cause of material rejection.

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For other concrete structures, deformed bars and mesh reinforcement - Grade 460 shall be used. It
shall be free of any contamination and rust indications. Chairs, tie wires and other devices used in
connecting, supporting, securing or fastening reinforcement in its correct position and level.
Contractor has to take necessary measures to protect erected reinforcement and starter bars from the
development of rust by covering with plastic sheets. All bars shall be cleaned to the satisfaction of
Employer/Engineer prior to place any concrete.
All bars for reinforcement and steel fabric reinforcement shall be stored on the site under cover on
timber or concrete supports suitably spaced and of sufficient height to keep the steel clear of the
ground.
Potential gradient reinforcement shall be provided for the earthing of the base slabs, whenever electro-mechanical equipment is installed and as approved by Electrical requirements
In buildings that contain electrical plant, the concrete reinforcing steel shall be earthed to ensure that
limits on step and touch potentials are not exceeded. An approved method shall be used for the tying
of reinforcing steel meshes such that is does not present a high impedance to fault currents to earth.
Depending on the Contractors design, additional steel may be added near to the surface of the concrete that is non structural to meet the step and touch potential limits and joined to the site earthing
system. This shall be installed in mesh formation.
The Contractor shall submit for approval, the method that is proposed and ensure that the sub contractor for the civil works installs the approved arrangement.
If the Contractors design also includes the placing of earthing conductors beneath buildings, this shall
be stated with the Tender together with the type of conductor and cross section. However no earthing
conductor or similar is permitted to penetrate any substructure water proofing system.
The connection of reinforcing bar to the copper earthing system shall be subject to approval.
7.8.7
Concrete mixes
7.8.7.1 General Description and Proportions and Mixing

The mix proportions are to be determined by proper mix design based on the requirements for
strength, workability and the particular site in which the concrete is to be placed. The Contractors
Concrete Engineer shall carry out the mix design. The design of mixes shall be based on the principles
of BS 5328 or DIN 1045.
Concrete Classification
L:
S1: Reinforced concrete in contact with groundwater, substructures, piles and pre-cast works.
S2: Reinforced concrete for superstructure
Plain concrete used for lean concrete, blinding, protection and flooring screeds , backfill etc.

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For flooring screed, strength after 28 days shall be minimum 30 Mpa and cement content 320Kg/m3
Concrete Class
Cube Strength At
28 Days In Mpa
Maximum Free
Water/Cement
Ratio
Max. Nominal
Aggregate Size In
mm
Min. Cement
Content InKg/M3
L
S1
S2
20
40
35
0.4
0.4
25
20
20
280
400
380
7.8.7.2
Consistency of Concrete
The amount of water used in the concrete shall be adjusted as required to ensure such a consistency
that it can be readily transported placed and compacted without segregation of the materials or bleeding of free water at the surface. Addition of water to compensate for stiffening of the concrete before
placing shall not be permitted. Consistency of the concrete shall be checked by slump tests and shall
not exceed the values given by BS 1881, Part 2 or DIN 1045, Part 1.
7.8.7.3 Mixing of Concrete

For mixing the concrete the mix design and constituents shall be available with the mixer operator. On
completion of the mixing operation, nothing more shall be allowed to be changed in the fresh concrete.
At the ready-mixed concrete plant, records shall be kept for every delivery (job record sheets). Each
delivery note shall be signed by an authorised person on behalf of the manufacturer and of the receiver. One copy shall be kept at the manufacturing plant and another on the Site and be included in
records referred to in the respective article.
In the case of ready-mixed concrete, the following information shall be given:
Quantity, strength class and consistency of the concrete, stating whether it is suitable for plain or
for reinforced concrete, and number of the type of concrete
Time of day at loading and unloading, number of vehicle
Statement that a statistical quality control is performed by an independent organisation.
Concrete mix particulars (cement type, aggregate, additives and admixture etc.)
Ready mix concrete supplier shall be a well established, locally based and approved by Authorities;
ISO-certified company and has long experience in the same field.
7.8.8
Transport of Concrete
Immediately after mixing, the concrete shall be conveyed to the place of use as rapidly as possible
using methods which will prevent the segregation, loss or contamination of materials. The concrete

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shall be placed and compacted within 90 minutes of the addition of water to the mix. Any concrete left
unplaced after this time shall be rejected and removed from the site.
The Contractor shall obtain permission at least 24 hours in advance of any concrete pour.
7.8.9
Concreting Operations
7.8.9.1 Inspection Prior to Concreting

All concreting methods shall be subject to review by the Employer/Engineer.
Concrete placing shall not be started until the Employer/Engineer has agreed all preparation of forms,
reinforcement, embedment, joints and all mixing, conveying, spreading, curing, finishing and protection equipment.
7.8.9.2 Placing of Concrete

Concrete shall be placed in the forms as close as possible to its final position in a single operation to
the full thickness of slabs and beams and shall be placed in horizontal layers, not exceeding 2.5 m
height in a single pour in walls, columns and similar members.
The Contractor shall organize the pouring of concrete in such a manner that once concreting of a section has started the operation shall be continuous and each operation shall be completed prior to a
stoppage.
The Temperature of concrete shall not exceed 30C measured at discharge into the works. Concrete
shall not be placed when the ambient temperature is 40C or above, or is above 37C and is rising.
The maximum allowable temperature of any point within any cast element is 60C. The maximum allowable temperature differential between any two points in the same element is 15C. Additional temperature control measures during construction will be required. Contractor to prepare a process control chart and method statement verifying measures to achieve these requirements.
Temperature monitoring of concrete work is required where:
The minimum dimension of any casting is 0.8 meters or more, or
Where otherwise instructed by the Employer/Engineer.
Concrete shall not be dropped into place from a height exceeding 2 meters. Trunking and chutes to
Employer/Engineer approval shall be used for any concrete to be deposited from a height exceeding 2
m.
Concrete which has partially hardened shall not be exposed to injurious vibration or shock, except for
controlled re-vibration where specified. When concreting of a certain large structural element is specified strictly as to be poured continuously, then the concreting operations shall be organized for day
and night working, in long shifts, as necessary.

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7.8.9.3 Compaction and Mechanical Vibration Of Concrete

As concrete is being placed it shall be compacted by mechanical vibrators, to obtain a dense material
free from honeycombing, free from water and air holes. For compacting the concrete, internal vibrators shall be used operating within a range of 5,000 to 10,000 cycles per minute.
The Contractor shall ensure that the vibrators are used in such a manner that the reinforcement is not
displaced, the formwork not damaged and no segregation caused, but complete compaction of the
concrete is achieved. Vibrators shall be in good working conditions and shall not show any leak of oil
or diesel.
7.8.9.4 Construction, Expansion and Contraction Joints

Joints are to be arranged by the contractor designer in such a way that stresses and strains caused by
settlements, temperature, differential settlement, do not adversely affect the structures. The settlement joints shall run through the complete structure down to foundation level, the expansion joints
however shall stop on the top level of foundations.
The joint width which is to be at least 2 cm is to be planned considering all relevant factors (settlements, tilting, movements and other aspects). Joint shall be filled and sealed with approved filler
boards and sealants.
The number of joints should be kept as low as possible consistent with reasonable precautions against
shrinkage and complying with the international standards.
Where it is necessary to introduce construction joints, careful consideration should be given to their
exact location, which should be indicated on the drawings. Construction joints should be at right angles
to the general direction of the member and should take due account of shear and other stresses.
All under ground joints or joints within fluids retaining structures (tanks, manholes, pit etc.) shall be
provided with an approved high quality and heavy duty PVC water bars.
Particular care should be taken in the placing of the new concrete close to the joint. This concrete
should be particularly well compacted. All joints shall be prepared and loose concrete shall be completely removed and surface shall be wet prior to proceed with concreting for next stage. For differential settlement controlling joints, proprietary items (dowels with sleeves) shall be provided as required.
7.8.9.5 Concreting At Night

When approval is given to carry out concreting operations (under control of the Employer/Engineer)
at night or in places where daylight is excluded, the Contractor has to provide adequate lighting at all
points of mixing, transportation and placing of concrete.
7.8.9.6 Concreting In High Ambient Temperature

ACI standard 305 - concreting in hot weather shall apply.

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The temperature of the mixed concrete shall not exceed 30C. The Contractor shall take special
measures in the mixing, placing and curing of concrete. These measures shall include the shading of
aggregates, spraying of aggregates with water, cooling of the mix constituents (introduction of ice to
the mixing water) and reduction of transportation time to the minimum. During placing suitable
measures shall be provided to prevent premature setting of concrete placed in contact with hot surfaces. All concreting areas, formwork and reinforcement shall be shielded from the direct rays of the
sun and sprayed with water when necessary. Covering freshly poured concrete with wet burlap or
similar covers
Attention to curing requirements is important at all times; it is especially so in hot, dry weather because
of greater danger of crazing and cracking.
7.8.9.7 Protective Measures for Fresh Concrete, Concrete Cover

In general the cover of rebars shall be as per ACI 318, BS 8110 or DIN 1045 taking into account the site
conditions (high temperature, humidity).
The minimum concrete cover shall be as follows:
Concrete parts above ground (external surface)
50 mm
Concrete exposed to underground and groundwater
75 mm
Slabs (internal)
30 mm
Beams and columns (internal)
40 mm
Immediately after the compaction of the concrete has been finished, the Contractor shall ensure adequate protection from the weather. Excessive drying can lead to crack formation as a result of plastic
contraction. The concrete surface shall be completely covered with a layer of 0.3 mm thick PVC-plasticfoil material, and kept constantly moist for at least 7 days.
Where large sections of concrete are poured, special precautions t shall be taken to reduce and dissipate the heat generated by the setting and hardening of the concrete (e.g. built-in cooling water pipe
system).
The minimum amount of reinforcement in accordance to the applicable codes and standards shall be
present to prevent shrinking cracks. This is applicable also for flooring screeds and mortars.
No load of any kind, however light, shall be allowed on concrete which has not properly set and the
Contractor shall prevent any load to be imposed on the concrete structures until it has been declared
by the Employer/Engineer to be ready to carry loads.
7.8.9.8 Repair of Damaged or Defective Concrete

Concrete which has completed its final setting shall be inspected by the Employer/Engineer and any
cracks, honeycomb areas, segregations. shall be marked. No repairs shall be carried out until directed

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by the Employer/Engineer. All concrete surfaces that will receive finishing works shall be free of undulations, cracks, board marks. Any kind of defects shall be repaired by an approved products (cement
or epoxy products) to the approval of Employer/Engineer.
7.9
QA/QC
7.9.1
Trial Mixes
Design of concrete mixes for different use shall be approved by Employer/Engineer.

Trial mixes shall be prepared, at the expense of contractor, prior the commencement of concreting for
the strength class of concrete and consistency. Making and testing of trial cubes shall be in line with
the standards (e.g. EC 2, DIN 1048 or BS 1881 and 5328). The followings minimum tests shall be carried
to verify the proposed mix design:
Testing of the raw material (aggregates, cement, wateretc)
Testing of the proposed admixtures and additives.
Compressive strength for 3, 7 and 28 days.
Concrete initial and final setting time, slump.
Concrete bleeding, air content, fresh and hardened concrete densities.
Concrete durability (permeability, absorption and RCP).
Chemical properties of hardened concrete.
Fresh concrete temperature shall be checked at different intervals and process of hydration and heat
generation shall be evaluated by the specialist.
All above tests shall be conducted for fresh concrete delivered to the site.
All sampling and testing shall be carried out by an approved independent third party laboratory accredited by DM.
The following criteria shall be the basis of mix design:
Absorption (I.S.A.T.)
10 mins:
0.05 ml/m2/sec
30 mins:
0.02 ml/m2/sec
60 mins:
0.005 ml/m2/sec
120 mins:
0.003 ml/m2/sec
Water Penetration DIN 1048
< 5 mm (with microsilica)

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AASHTO T277 Rapid Chloride:
<800 coulombs
Air content
< 1%
Absorption (BS 1881)
< 2%
Test cubes from trial mixes shall be made and tested in accordance with BS 1881, Part 3 or DIN 1048,
Part 2. Number of samples and cubes shall be agreed by Employer/Engineer.
As per BS 5328, three separate batches of concrete should be made, workability of each batch determined and three test cubes shall be made from each batch for each age (e.g. for 7 and 28 days) at
which tests are required. The strength shall conform to target mean strength as per BS 5328, - Requirements for designed mixes.
The appropriate strength requirements may be considered to be satisfied if none of the strengths of
the cubes is below the required characteristic strength and if the average strength of the nine cubes is
not less than recommended by BS 5328, trial mixes.
All test results will have to comply with specification requirements before approval given to the mixes
design.
7.9.2
Quality and Testing
No more than 5% of the test results my fall below the 28 day specified strength. Making and curing of
test specimens shall be in accordance with BS 1881 Parts 108, 109, 110 and 111.
All mixes can only be placed following approval by the Employer/Engineer. The mean strength shall
exceed the characteristic strength by a margin of 1.64 times the standards deviation expected from
the batching plant. However, no standard deviation less than 3.5 N/mm2 shall be used as a basis for
designing a mix.
If the results are less than those specified, the Employer/Engineer must suspend all concreting work
and order further tests. Any concrete found not to comply with the specification shall be broken out
and replaced to the satisfaction of the Employer/Engineer.
7.9.3
Strength of Concrete
7.9.3.1 Testing Of Fresh Concrete By Means Of Test Cubes

All test cubes shall be made and tested for compressive strength in accordance with BS 1881 - Method
of testing concrete or DIN 1048, Part 1 - Test methods for concrete, fresh concrete, hardened concrete
as separately prepared test specimens.
A minimum of seven test cubes shall be made on each concreting day of columns, walls and minor
foundations. Additional samples shall be made for durability checks and chloride/sulphate contents
for major pours, slabs, and raft foundations. The concrete for test samples shall be taken directly from
the concrete mixer and shall be handled (vibrated etc.) and cured under similar conditions to those

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prevailing during the construction. The moulds for the test cubes shall be made of steel. Testing Of
Concrete in Structures
The types of tests described hereinafter are applicable to the finished parts of the structure. They may
be used in routine inspection and for quality control.
Type of tests:
Cutting cores: The procedure used shall comply with the requirements of DIN 1048, Part 2 or an
agreed equivalent standard.
Gamma radiography: The testing shall be carried out in accordance with the requirements of Part
3 of BS 4408 or equivalent.
Ultrasonic test: Such tests may be used to obtain approximate indications of the strength of the
concrete in the structure (BS 4408, Part 5).
Electromagnetic cover measuring: Such tests may be used to verify the position of the reinforcement and shall be in accordance with the requirements of design (BS 4408, Part 1).
Rebound hammer test: Such tests may be used to obtain approximate indications of the strength
of the concrete.
Load tests of structures or parts of structures: If the results of the above mentioned check tests
show that the quality of the materials is inadequate or if other defects are revealed, the Employer/Engineer may require a loading test to be made.
If the result of the test is not satisfactory, the part of the defective works concerned shall be taken
down or cut and reconstructed by Contractor to comply with specification.
All the costs for the above mentioned tests shall be borne by the Contractor.
7.9.4
Reinforcement Certificates
Each consignment of steel reinforcement shall be accompanied by a test certificate from the manufacturer showing that the steel has been tested and analyzed and the date of such tests and analyses and
that such tests and analyses comply in all respects with the standards.
The following tests shall be carried out on reinforcement
Chemical analysis, carbon equivalent value
BS 4449/4461
Tensile strength, yield stress, elongation
BS 18
Bend and re-bend test
BS 4449/4461
Other tests as per ASTM A775 for coated bars.

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Further, samples from each delivery to the site shall be collected ant tested to verify compliance with
approved materials.
7.9.5
Shuttering and Scaffolding Works
The formwork drawings and details shall be prepared by a specialist approved by Employer/Engineer.
Erection of formwork and its supporting structures shall be under the direct supervision of the designer/material supplier. Concrete shall not be placed unless a written release is obtained from the
designer/supplier.
Back propping/props shall be installed immediately after striking of formwork to minimise deflections.
It shall remain in position for long periods as much as possible.
All materials shall be of good conditions and not showing any defects (buckling or deformation). It shall
be used as per the design loads.
All supporting vertical elements shall rest on well prepared and sound surfaces. Direct supports on soil
are not allowed. Erection and installation shall follow the safety requirements.
Marine plywood and white wood shall be new and free of any defects. It shall be placed in line and
level as per the structural elements dimensions. Shutter accessories like tie rods shall be placed strait
and not inclined. Tie rods passing through walls of fluids retaining structures, manholes and cable
trenches shall be provided with approved GI cast iron waterstopper.

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Pre-cast Concrete
It shall comply with concrete requirements works as specified above.

All pre cast concrete works shall be done by an approved specialized Manufacturer. Complete details
and shop drawings shall be approved by Employer/Engineer prior to start any production.
Particular to precast concrete covers for ducts and trenches, width shall not exceed 40 cm for easy
handling and shall be designed to carry the heaviest loads that will cross over.
For handling and lifting, covers shall be furnished with proprietary, lifting lugs embedded in concrete
from HILTI or similar and of sufficient loading capacity.
All edges of precast covers shall be protected by GI and painted edge angles.

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Grouts
Only non-shrink grouts, which is either cementitious or epoxy grouts, shall be used. Grouts deriving
their non-shrink properties from metal oxidising (i.e. an increase in volume of metal due to oxidation)
shall not be allowed. Compressive and flexural strengths of the non-shrink grouts shall be as follows:
Properties of Grouts
Type of
Consistency
Grout
Cement type
Epoxy type
flowable
High flow
Compressive Strength (N/mm2)
Flexural Strength (N/mm2)
7 days
45
80
7 days
8
25
28 days
65
28 days
10
All grouts for rotating machines including turbines and generators shall be responsibility of the equipment supplier/contractor, who shall be responsible for its execution and guarantee. The Contractor
shall ensure that the proposed type of grout is suitable for the thickness of the gaps between concrete
and base plates as well as for the dimensions of the pockets.
Generally epoxy grout should be used for reciprocating machinery, heavy cranes, prime movers, e.g.
turbines, diesel engines, high output pumps, chimneys, boilers, large transformers, etc. cementitious
grouts shall be used mainly for base plates of steel structures, small pumps, crane rails, etc. The Contractor shall propose the type of the grout for Employer/Engineers approval.
Samples from grouts mixed at site shall be collected and tested to verify its compliance with approved
materials

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10
Masonry, Mortar, Plaster
10.1
The scope of work covered by this division shall be deemed to comprise the supply and installation of
all brickwork and concrete blocks, solid partition walls shown on plans and as specified inclusive mortar
and plasterworks or as fair-faced masonry works. It shall also include the supply of the appertaining
materials and structural parts, scaffolding, offloading on site and all operations in connection with masonry works.
10.1.1 Cement Mortars

Mortar for block work shall be cement mortar, with the proportions 1:3 to 1:4 for cement to sand. All
mortar shall be mixed in a power driven mixer, in quantity for the work immediately in hand and all
materials shall be screened before mixing. Sand and cement materials shall be as specified for concrete
works.
Damp proof courses shall provide a barrier to the passage of water from the exterior of the building to
the interior and from the ground to the building or from one part of the building to another.
Any admixture shall be proposed for review by the Employer/Engineer. Admixtures shall comply with
the foregoing Standards. If no standard is applicable to the proposed admixture, the Employer/Engineer may order trial mixes to verify the suitability of the admixture. The cost of these tests shall be
borne by the Contractor. The use of chlorine based admixture is forbidden.
10.1.2 Masonry
This Clause covers all brick work, concrete block work, damp-proof courses, natural stone and mortar.
Any related concrete work and the reinforcement shall comply with relevant Clause of this specification. Unless otherwise specified, the following standards shall apply:
BS
DIN
6073
Masonry
5628
Code of practise for masonry
1053
Masonry works
4103
Lightly constructed partitions
Alternatively, masonry may be design in line with the Uniform Building Code (UBC).
Dubai Municipality Advisory Notes shall be considered.
Locally available bricks of the strength in accordance to the applicable Codes and Standards or locally
fabricated concrete masonry units shall be used. The size of concrete blocks shall normally 400 mm
long, 200 mm high and 100mm, 150 mm, 200 mm in width. Their average compressive strength shall
not be less than 10.0 N/mm2. Samples of concrete blocks shall be tested as per BS 6073and approved

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by the Employer/Engineer before being used. For load bearing walls the minimum strength shall be
15.0 N/mm2
Lintels and reinforced concrete frames shall be provided at all openings. Lintels and frames shall be set
flush with the wall face, with rough surfaces to provide key when the wall is to be plastered.
For all internal/external walls exceeding 3.0m in height and 6 meters in length supporting reinforced
concrete stiffener beams and columns shall be designed and shown on the drawings.
For air conditioned rooms, external walls (150 mm+ 70mm+ 100mm) shall be double skin wall with 50
mm (32 kg/cm2) extruded insulation layer in between. These materials shall be capable of resisting
insects and fungi and shall be A1, A2 or B1 material acc. to DIN 4102. Thermal insulation co-efficient
of the external wall shall have a U-value of 0.25 W/m2K but shall not exceed DM and Green buildings
requirements All internal block walls shall be 200 mm thick.
For internal block walls, all block accessories (reinforcement mesh, cavity ties, lugsetc) shall be galvanized and shall be provided every second course and fixed by mechanical means. External block walls
accessories shall be of SS and installed as for internal walls.
Curing of concrete block masonry walls shall be done for a minimum period of five (5) calendar days.
10.1.3 Plaster
This Clause covers all internal and external plastering for buildings and structures, etc., including all
metal accessories. Works and materials shall generally comply to DIN 18350, with cement and water
as stated under Concrete and Reinforced Concrete.
All surfaces to be plastered shall be clean and free from dust, grease, loose mortar and any traces of
salts, and shall be brushed down by wire brush to remove any loose material. Joints in block work shall
be raked out to a depth of 10 mm minimum. Smooth concrete surfaces shall be roughened by hacking
or brush hammering. All surfaces to be plastered shall be thoroughly sprayed with potable water before plaster is applied.
Junctions between different material (other than between the main reinforced concrete member and
the brick or block walls) shall be reinforced. The reinforcement shall be embedded completely in the
undercoat of plaster. Plaster lathwork, chicken wire, expended metal shall be of non-corrosive stainless steel material.
Where junctions are between main concrete elements (beams, columns etc.) and brick or block work,
definite breaks shall be carried out through the plaster finish by stop beads or similar. Plaster accessories such as stoppers, corner beads etc. shall be provided. Joints shall be sealed with approved material.
All surfaces to be plastered initially shall be hopper sprayed to form a key coat. The key coat shall be
cured for a minimum of 4 days by water, and all free water shall disappear before the application of
the finished coats.
Only proprietary ready mix plaster materials approved by Employer/Engineer shall be used for the
under and final coats. Manufacturer shall provide his standard guarantees for work under this section.
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The rendering shall be moist cured for a minimum of 4 days by water, and shall be allowed to dry
before applying the finishing coats. Top of block walls under soffit and beams shall be covered with a
flexible board material. Walls shall be connected to soffit/beam as per the required standards.
10.2
Execution
All execution works must be in accordance with standards and normal practices to the state of the art.
All plastered surfaces shall be even and straight, smooth and free of working joints and shall be sound.
Before laying the blocks, it shall be continuously sprayed by fresh water to avoid absorption of water
existing the mortar mix. All wall cavities shall be kept clear and cleaned from mortar droppings.
All materials and methods of application shall be submitted for approval by Employer/Engineer.

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11
Steel Work
11.1
All steel works, design and construction shall be carried out in accordance with relevant British or German standards.
However the complete works shall be covered by one standard only in the respect of the static analysis,
the final design drawings and the profiles to be used. In the case of structural steelwork, care should
be taken that all parts in the assembly fit accurately together and corresponding parts should preferably be interchangeable. Forcible correction to fit the members together will not be allowed.
The Contractor shall submit to the Employer/Engineer for approval the country of origin and manufacturer of the steel he proposes to supply.
The contractor has to design, prepare and submit the complete shop drawings to the Employer/Engineer to get the approval before start of the fabrication. All structural steel structures, design, shop
drawings and connection details shall be approved by a third party designer prior to start execution.
11.2
11.2.1 General
The design and construction of steel structures shall be based on:
Eurocode 3, Design of Steel Structures,
Eurocode 4, Design of Composite Steel and Concrete Structures (DIN V ENV 1993-1-1, DIN V
ENV 1993-1-2, DIN V ENV 1994-1-1 and DIN V ENV 1994-1-2) or
British Standards conform to the these EUROCODES.
Basis for the execution of all works shall be DIN 18 800, Structural Steel Work:
Part 1: Design and Construction
Part 2: Analysis of Safety against Buckling of Linear Members and Frames
Part 3: Analysis of Safety against Buckling of Plates
Part 4: Analysis of Safety against Buckling of Shells
Part 5: Composite Structures
Part 7: Execution and Contractors Qualification

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Steel and steel properties shall comply with requirements of DIN EN 10 025, and DIN EN 10 027, Designation System for Steels and the standards of the DIN 18 800 series. Reference Standards indicated
shall also be observed.
All steel shall be carefully stored and handled so that pieces are not subjected to excessive stresses or
damage.
The Contractor shall include for the preparation of all shop details by competent persons.
Every drawing shall show the number and sizes of all bolts, complete details of welds, type of electrodes, welding procedure, and any other relevant information like the connections to reinforced concrete construction members, the fixation of power plant facilities and the connection to roof and wall
claddings.
The Contractor shall be responsible for the correctness of his shop details and site connections. The
steelwork shall be manufactured by a specialist firm approved by the Employer/Engineer.
All steelwork before and after manufacturing shall be smooth, un-deformed, straight and free from
cracks, twist and burrs.
All steelwork shall be cut and fabricated to a tolerance in accordance to DIN 18203 Part 2. Each plate
shall be truly at right angles to the longitudinal axis of the section. No work shall be painted, packed or
dispatched from the manufacturer's workshop until it has been tested, and complies with, or has been
certified to comply with, all the tests and requirements of the standard applicable to the material specified and until it has been inspected and passed by the Employer/Engineer.
11.3
Materials
11.3.1 General
As far as possible standard profiles shall be used according the static calculation.
Minimum plate thickness for steel structures shall be 6 mm for webs and 8 mm for flanges respectively.
Welding shall be in accordance with Structural Welding Code of American Welding Society (AWS D1.1)
ASTM A-325 for high strength friction bolts and ASTM A-307 for other bolts may be considered
11.3.2
Steel Specifications
All miscellaneous steel shall conform to grade DIN EN 10 027 S 235 or equivalent standards as BS,
ASTM, JIS, etc.
The following listing summarizes material standards and specifications, as well as minimum material
requirements for design, manufacture and erection:
MEMBER
STANDARD
MATERIAL
Built-up Members
DIN EN 10 027-1
all steel brands S235 and S355

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MEMBER
STANDARD
MATERIAL
Formerly DIN 17100 Formerly St, USt & RSt37-2, St37-3, St52-3 or
and EN 10 025
Fe360B, BFU, BFN, C & D1, and Fe 510
DIN 1024 Series DIN
all steel brands S235 and S355,
1025 Series
Hot Rolled Members
DIN 1026 Series DIN

Formerly St, USt & RSt37-2, St37-3 and St521027 Series DIN 1028
3; or Fe360B, BFU BFN, C & D1, and Fe 510
Series
DIN 1029 Series
Tubes
DIN EN 10 210-1,2
S235 and S355
Bolts and Anchor Bolts
DIN ISO 898, DIN 18

4.6 (fy 240 N/mm) 5.6 (fy 300 N/mm)
800-1
High Strength Bolts
DIN ISO 898, DIN 18

8.8 (fy 640 N/mm) 10.9 (fy 900 N/mm)
800-1
DIN 32 500, Part 1 &
4.8 (fy 320 N/mm)
DIN 18 800-1
Stud Bolts
DIN 32 500, Part 3 &
St 37-3 per DIN 17 100, (fy 350 N/mm)
DIN 18 800-1
11.3.3
Galvanizing
Refer to Clause 1.4.5.
11.4
Execution /Workmanship
11.4.1 Tolerances
Care shall be taken to ensure that the tolerances specified on the drawings or the relevant standards
BS 449 Part 2 or DIN 18203 Part 2 are executed. Also, refer Clause 1.4.3.
11.4.2 Connections
Field connections shall be friction-type or bolted type connections with ASTM A-325 or equivalentbolting with heavy hexagonal head bolts. Connections at building expansion joints must be slotted with
shoulder bolts with locknuts. The slots shall be of sufficient length to permit movement of sliding,
member in both directions from the neutral position, of 25 mm.

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Where no reactions or moments are called the connections for indicated sections shall be designed
with maximum number of fasteners of 7/8" (M22) minimum diameter.
No connections shall have less than two bolts.
Diagonal bracing shall be properly drawn by shortening the member 1/16" every 10 ft. of member
length. The connections at end bracings shall develop the force due to the design load, but not less
than 50 percent of the effective strength of the member. If no load is indicated, the latter condition
shall govern.
In accordance with the structural design, the steel structure may be either a frame structure and/or a
braced structure. Following notes shall be considered during execution and erection of structural steel
works:
Co-ordination of the design of the structural steel members with the design of related concrete
structures
Checking of anchor bolts and their setting prior to casting pedestals/foundations
Complete erection of the steel structure in accordance with the agreed erection drawings
The size of construction members shall be of the maximum admissible size for the transport to and
handling at site. Fabricated steel structures shall be pre-assembled in the workshop to such an extent
to ensure proper field erection, and shall be dismantled (non welded/bolted members only) for transportation, during which the contractor shall reasonably protect the steel structure from damages. The
steel structure shall be suitable packed, cover or coated, and any damage and corrosion during transportation shall be the responsibility of the contractor.
Torque wrenches shall be used for tightening of bolt connections. Structural steel members delivered
to the site shall be evenly supported and stacked on timber to avoid deformation.
Bolts, nuts, washers, rivets and other identical items of structural steel required to be incorporated
into concrete shall be delivered to the Site well in advance.
Bolts, pins, packings, tools, insulation material, electrical parts, motors, parts with electrical devices,
attached instruments, welding equipment and material shall be stored inside closed stores.
All metal parts shall be interconnected to the Stations earthing system as specified in electrical specifications.
Tolerances shall be kept in accordance with the relevant stipulation of DIN 18203 Part 2 or BS 449.
11.4.2.1 Cutting
Cutting may be by shearing, cropping, sawing or machine flame cutting. Hand flame cutting is subject
to review by the Employer/Engineer.
Cut edges on rolled products must be given a finishing operation by a metal cutting method (e.g. by
planning, milling, grinding or filing). Notches and cracks are to be eliminated in the same way.
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Small surface defects such as grooves and other types of unevenness may be removed by grinding. The
use of welding to fill in defects is generally not permitted.
11.4.2.2 Bolt Holes

All holes are to be drilled and not punched after the members are assembled and tightly clamped or
bolted together. Punching may be permitted before assembly, provided the holes are punched 2 mm
less in diameter that the required size and reamed after assembly to the full diameter. The thickness
of material punched shall not exceed 10 mm.
For tolerances the requirements of BS 449 Part 2 or DIN 18203 Part 2 shall be observed.
11.4.2.3 Bolting
The threaded portion of each bolt shall project through the nut at least three full thread. Agreed high
strength friction grip bolts, preferably the type with indicated load are to be used where specified and
are to be tightened strictly in accordance with the manufacturer's instructions and the pertaining regulations. The surfaces in contact shall not be painted and shall be free from oil, dirt, loose rust, burrs
and other defects which would prevent solid seating of the parts or interfere with the development of
friction between them.
When connections are made using high strength friction grip bolts the "provisional directions for the
calculation, execution and structural design of friction grip bolted fastenings (high strength friction grip
fastenings)" prepared by the German Committee for Steel Construction are to be observed.
11.4.2.4 Welding
The execution and testing of welding shall be in accordance with the
British Standards BS 5135 or German Standards DIN 18800 and DIN EN 10025. All welds, unless otherwise stated are to be continuous minimum 6 mm fillet weld and shall be dressed smooth, free from
porosity, cracks, holes and finished to match adjacent surfaces. When welding operations are completed, all welding flux shall be removed without delay. After welding, the components should possess
the shape planned for them preferably without any subsequent dressing. The cooling of welds must
not be accelerated by any special measures.
Site welding is to be restricted to the absolute minimum and if cannot be avoided, procedure shall be
submitted for Employer/Engineer approval considering protection of the surrounding erected equipments and services.. The examination of welded work and the inspection of welds during and after
manufacture is to be carried out by responsible specialist welding engineers. Welding shall be carried
out by expert tradesmen and in strict accordance with the current code of practice.
For site welding, all welders shall be obliged to pass qualification tests to determine their ability to
perform such type of work. They shall provide necessary certificate from specialized agencies. For steel
structures, the Contractor shall carry out X-ray tests, ultrasonic testing or magnetic particle testing as
approved by Employer/Engineer for at least of 10 % of all welds by approved experienced representatives of a firm licensed for welding and testing.

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11.4.3 Painting
Surface treatment and painting before and after delivery to site shall be in accordance with the Tender
Document Volume II, Part G05.5 Corrosion Protection and Painting.
Parts to be encased in concrete shall not be painted or oiled. Surfaces inaccessible after shop assembly
shall receive the full specified protective treatment before assembly.
11.4.4 Erection
The Contractor must prepare and submit to the Employer/Engineer for approval a delivery and erection schedule of all structural steel work on site. This schedule must show the supply fabrication, delivery, assembly, erection and painting of the steelwork. Approval by the Employer/Engineer of any of
the construction and erection methods or plant shall not in any way relieve the Contractor from his
responsibilities under the contract.
The Contractor shall supply all suitable plant, hoisting gears and tackles for the erection of the steelwork and shall provide all temporary tie ropes, struts, shores and scaffolding..
The positioning and levelling of all steelwork and the accurate placing of every part of the structure
shall be in accordance with the approved drawings.
During erection, the work shall be securely bolted or otherwise fastened and if necessary temporarily
braced, so as to make adequate provision for all erection stresses and conditions. Neither permanent
bolting nor welding shall be done until proper alignment has been checked by Employer/Engineer at
site.
The Contractor shall supply all necessary false work and staging, tools, temporary connections, erection plant, service bolts, nuts, washers, anchorage cables, bracing and all other materials necessary to
carry out the work and shall remove the same as the progress of the erection permits.
Encased steelwork and steel in foundations shall be solidly encased in concrete, with a minimum cover
of 100 mm. All erection works shall be executed in a safe manner and bolts shall not be left without
complete tightening.
After completion of erection works, bolt tightening shall be checked to verify the required torque values for the different sizes of connection bolts use are achieved.
11.4.4.1 Footings
Foundation bolts and plates or steel stubs shall be provided for all columns and shall be firmly keyed
and grouted into concrete foundation blocks.
The Contractor shall set column bases and beam plates on non corrosive steel wedges or angle screeds,
to accurate elevations approximately 4 cm clear of masonry or concrete. Wooden wedges shall not be
used.

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Anchor bolts and other identical items of structural steel required to be built into concrete with instructions and/or templates for their installation shall be delivered to the respective trades in proper
time to avoid delay in the work. The structural steel erector shall verify the position of anchor bolts
before concrete is poured.
Levelling of base plates shall be by means of levelling screws. Setting procedures shall be as agreed by
the Employer/Engineer.
Shims for columns base plates, equipment base and at any other locations shall only be of non-corrosive material, in case of dissimilar metal to galvanized base plate, suitable protection shall be provided.
No carbon steel or other corrosive metal embodiments are permitted.
Grouting shall be provided with non shrinking mortar only. Type and class of non shrinking mortar is
subject to the approval of the Employer/Engineer.
11.4.4.2 Aligning and Plumbing

The Contractor shall provide all necessary people and braces to insure the alignment and stability of
the structural steel members until all are properly connected and riveted. All temporary people and
bracings shall take care of all dead load, wind load, seismic load and erection stresses, and shall remain
in place until, in the opinion of the Employer/Engineer they can be removed without danger to the
stability of the structure.
After erection, no column shall have a deviation from the vertical exceeding 1 to 1000 of the total
height of the column. This tolerance is including all other specified tolerances with the applicable
standards. Crane girder alignment and flange top level shall be check prior to handover to other discipline for crane rail installation.
Agreed steel gauges of the stud type or any kind of instrument shall be provided to enable the Employer/Engineer to carry out such checking of members as he may consider necessary. Grouting below
column base plates shall commence after verticality and bolt tightening are checked and accepted by
Employer/Engineer.
11.4.4.3 Correction of Errors

Correction of minor misfits and a reasonable amount of reaming and cutting of excess stock from rivets
will be considered as a legitimate part of erection. Any error that may occur in shop work which prevent the proper assembling and fitting of parts by moderate use of drift pins, or a moderate amount
of reaming and slight chipping or cutting shall immediately be called to the attention of the Employer/Engineer and an agreed method or procedure of correction shall be obtained or such method
or procedure shall not be employed. The use of cutting torches to enlarge or alter bolt or rivet holes
shall be prohibited.
11.4.4.4 Rejection
Any steelwork which in the opinion of the Employer/Engineer is not in accordance with the requirements of the Standards or with the Specification, shall be rejected and removed from the site at the
Contractors expense.

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11.5
QA/QC
The manufacturer's test certificate (mechanical tests and the chemical composition) for all steelwork
shall be supplied to the Employer/Engineer. The Contractor shall provide free of charge any supplementary tests reasonably required by the Employer/Engineer. At least three (3) samples of each profile
section/manufacturer/batch shall be collected and tested at an independent testing station in accordance with BS 5400 - BS 4872 or DIN EN 10025, DIN 18800 and DIN 18801. If the results of the tests are
unsatisfactory the whole quantity of steel which the sample represents shall be rejected at the expense
of the Contractor. No steelwork shall be delivered from the manufacturer's works until it has been
tested and the results comply with the requirements of the relevant BS or DIN.
Apparatus, equipment and tools required for testing (e.g. for X-rays) shall be part of the scope of supply, with following tests at least required for welds:
X-ray tests for each heavy load bearing structure member: min. for 10 % of all welds
Also refer to other clauses of this specification for welding and in general for testing, the most stringent
of which shall apply.

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12
Small Non-Structural Steel Parts
12.1
General
This sub-clause refers to the specification covering the provision of all materials and labour in relation
to the supply, manufacture, on site of articles made of steel or cast iron.
All steel structures and parts specified under this sub-clause shall be hot dip galvanized and painted
according to Tender Document Volume II, Part G05.5 Corrosion Protection and Testing.
The list of small items to be furnished shall contain but not be limited to the following:
Structural steel stairs, platforms and walkways, railing for stairs, platforms, walkways and protection around floor openings, corner and edge protection for concrete steps and concrete covers,
support of any equipment foundation, anchors, ties, hangers, inserts or any embedded steel parts.
Steel pipes and plain round bars for making guardrails and ladders
Steel plates, chequered and/or flat, for fabrication of removable covers
Open steel grating for metal steps, platforms, walkways.
12.2
Design /Engineering
12.2.1 Steel Sections and Plates

Steel sections may be required in various standard profiles and shall comply with the relevant standards specified herein. In general, these sections must be straight, with exact measurements and made
of mild steel as described under clause "Structural Steel" above.
Where required, mild steel plates shall be bent to special profile forms. These bent plates shall be used
particularly on stairs, and also on doors and window frames.
12.2.2 Chequered Plates

Chequered plates shall be at least 8 mm thick, heavy duty type and hot dip galvanized. All chequered
plates shall be provided with fasteners and shall rest flat on their supports without rocking, and their
deflection shall not exceed 1:250 of the span. All edges of plates shall be ground or cut, smooth and
straight with 3 mm clearance between plates. Removable chequered plates shall be of a size permitting
easy handling and shall be provided with two lifting holes. Where and if required, non-braced chequered plates shall be stiffened by angles.
Chequered plates fitted to supporting members shall normally be secured by countersunk, flathead
bolts or screws. Cut-outs and openings required in chequered plates shall be shop formed and adequately reinforced as per the agreed drawings or Employer/Engineer instructions.

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The contractor shall furnish banding strips or angles for openings required to be cut in the field, as well
as all other necessary accessories for chequered plate installation at site. The type of chequered plates
to be installed shall be subject to Employer/Engineer approval.
12.2.3 Metal Flooring

The thickness of chequerred plate or construction of grating shall be sufficient to bear the load of
applicable equipment or traffic and shall in every case be capable of bearing a uniform load of not less
than 5 kN/m2. In addition to the minimum requirements of strength, a minimum chequer plate thickness of 8 mm and a grating member minimum thickness of 5 mm shall be guaranteed. Where welded
construction is used on grating the welding shall be continuous and on the both edges of a joint.
Metal flooring shall in all cases be supported by a properly formed steel kerb running continuously
throughout the supported length. The chequered flooring shall be provided with proper and adequate
lifting eyes.
The arrangement of panels, unless otherwise prescribed, shall allow the ready removal of every unit
by not more than two men. The top of the flooring item shall be flush with the finished surface of the
concrete floor.
12.2.4 Steel Grating

Steel grating shall be welded type of rectangular pattern of parallel bearing bars of 45 mm depth and
5 mm thickness and at 30 mm centres with twisted cross bars at 100 mm distance, unless otherwise
indicated on the drawings.
Gratings shall be hot-dip galvanized after fabrication. All grating indicated as removable shall be bolted
or clipped to supports. Sizes of grating shall be such as to afford easy handling. The contractor shall
cut, as shown on all certified drawings, neat, circular or square openings for the passage of pipes, ducts,
etc., through gratings. The contractor shall provide toe plates at all unprotected open sides at ends of
grating and where shown on drawings and the contractor shall weld bands made of steel plate matching the toe plate height at all openings. All gratings shall be arranged so that bars in either direction
are aligned.
Bearing bars shall be of depth required to support the design loads at allowable stresses and a deflection not exceeding 1/250 of span length.
12.2.5 Ladders
Ladders shall be provided by the contractor to all heights and accesses as required in the design, e.g.
to reach roofs, basements, emergency exits, etc. Side-rails of ladders shall consist of 75 x 10 mm flat
bars, or suitable channel sections as per design requirements. Rungs shall be of 25 mm diameter bars
with anti slip surface, tenoned into the side rails and securely welded. Rungs shall be 0.4 m long between side-rails and spaced 28 cm.
Ladders shall be securely fastened at top and bottom into the wall and shall have intermediate clips or
flats and fastenings spaced not more than 2.0 m apart. Clips or flats shall be riveted or welded to the
side.

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Ladder shall be constructed staggered with landings at every 10m in height.
Ladders exceeding 2.5 m length shall be equipped with safety cages starting 2.50 m above ground or
floor, and extending over the full height of the stringers with an unobstructed inside diameter of at
least 0.7 m.
The safety cage shall be constructed from 55 x 6 mm flat steel bar hoops, bent to the specified radius
and spaced uniformly and horizontally at a maximum of 1.5 m and 5 equally spaced 40 x 6 mm vertical
flat bars, welded to the inside face of hoops to provide a smooth and snag-free interior of the cage.
12.2.6 Steel Stairs

Steel stairs shall be in accordance DIN 18065:2015-03. Main stairways shall have a minimum clear
width of 1,000 mm.
Steel pipe railing shall always be installed on both sides of all walkways, stairs and platforms, and shall
be made of steel pipes of 42.16 mm outside diameter and minimum thickness of 3.56mm (DN 40,
schedule 40). The top rail shall be at a height of not less than 1,100 mm from the walkway or platform
level. Rails over stairs shall have the top level at a height of 900 mm above the nose of the tread. Two
intermediate rails shall be installed between the top rail and the toe plate or channel. A pattern of
symmetry shall be accomplished when locating pipe posts and the distance between pipe posts shall
not exceed 1,200 mm.
Pipe railing shall consist of standard steel pipe with flush, continuous, welded joints, ground smooth
hot dip galvanized and painted. Exposed bottom ends of pipe posts shall be closed where required.
For stairs with concrete/block side walls, Wall pipe and handrail shall be returned to a wall and be
provided with necessary secure anchors. The contractor shall provide necessary handrail brackets of
malleable iron and anchors. All accessories such as floor flanges, etc., required for pipe railing shall be
furnished.
Installation of pipe railings shall be done in a substantial and rigid manner. Stands on concrete shall be
set in pipe sleeves, not less than 4 inches deep, with the sleeves cast into the concrete and of a size
fitting snugly around and thus rigidly supporting the pipe shall have a flange on the foot secured to the
concrete by countersunk, flat-head machine screws in expansion metal sleeves.
Stands on metal shall have a plate or flange welded to the foot and secured by counter-sunk, flat-head
machine screws tapped into the supporting members, or as indicated on the drawings.
Removable sections shall be made in sections as above specified. On steel, foot plates shall be welded
to the stands and fastened with cap screws.

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13
Waterproofing
13.1
General
This clause is applicable for substructures waterproofing, roof waterproofing and all above ground wet
areas as HVAC rooms and toilets.
Roof waterproofing shall comprise of a 4 mm thick APP bitumen membrane with non-woven polyester
reinforcement of a minimum 400 g/m2 torch applied laid over the concrete cast to slopes towards the
rain water down spots and roof drains/roof outlets, covered with a minimum 50 mm extruded polystyrene insulation board of a minimum density of 40 kg/m3, separation/geotextile layer of 180 gm/m2
followed by mortar and precast concrete tiles. Thickness of insulation board can be increased to meet
HVAC design requirements and DM Green Buildings Regulations.
Wet areas of suspended slabs shall be waterproofed with two layers of 4 mm thick SBS modified bituminous membrane separated with a minimum of 50 mm of mortar to the Employer/Engineer approval.
For Waterproofing of sub structures and foundations , basements and underground tanks, Trenches,
cable pits, drainage manholes, cable ducts these shall be tanked and protected externally with 4mm
thick SBS modified bituminous membrane having non-woven polyester reinforcement of a minimum
of 260 g/m2. Minor structures, like buried protection slabs, light pole foundations, and fence foundation shall be painted with two coats of coal tar epoxy coating and protected with 1,000 gauge polythene sheet.
Provided membrane for substructures shall be protected from damage by concrete screed or protection board as approved by the Employer/Engineer. All roof and substructure membranes shall be terminated in a groove covered with aluminium flashing (1mm thick) and sealant to form a water tight
construction. Fasteners shall be made of aluminium or SS 316.
All components of the system shall be obtained from the same supplier. The application of the waterproofing system shall be carried out by the manufacturers standard applicators approved by Employer/Engineer and in accordance with the manufacturers instructions and specifications. Shop
drawings/ typical details and method of application shall be submitted by contractor for approval.
The waterproofing systems shall be guaranteed for 10 years for material, workmanship and other liabilities which may be caused by leaks/failure of the system. The guarantee provided by the Contractor
shall be supported by manufacturers guarantee for the same period.
All roofs and wet areas shall be tested by flooding with water with a minimum 50 mm height for 36
hours. The Test shall be repeated after completion of tiling and related ancillary works.
13.2
Roof drains
Roof drains (wall or floor type) of approved heavy duty and corrosion protected cast iron material shall
be installed. The roof drains shall be capable of receiving the terminations of the waterproofing membrane.

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13.3
Rainwater/Gutter down pipes
For concrete and structural steel buildings and sheds, gutters and rainwater pipes shall be provided
and connected with the main storm water system through a catch pit constructed directly under the
down pipes. The materials shall be powder coated aluminium of suitable gauge, but at least 0.75 mm
for gutter and 2 mm for pipe, with a finish matching the colour of the cladding/external finishing. Heavy
duty hot dip galvanized and powder coated pipe clips shall be installed at 2.0 m intervals .
Clean outs shall be provided where ever required and as per approved design drawings and calculations of the rainwater collection system. All connections shall be made watertight and tested for leakage in presence of Employer/Engineer representative.

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14
Metal Works Roof and Wall Cladding Systems
14.1
All structural steel buildings, such as machine hall, etc. shall have insulated sandwich cladding for roofs
and walls. All roof sunshades may be provided as single sheets. The roof and wall cladding specification
described below sets out the general requirements for cladding and the use of standard trapezoidal
cladding for main structures such as the turbine halls. However , any other requirements called by
local authorities regarding quality of material, quality of insulation and fire fighting protections shall
be followed by Contractor. Fire tests certificates attested by local authorities or local independent laboratory shall be provided along with materials submittal.
14.2
Warranties
warranty in form acceptable to the Employer/Engineer, jointly signed by Contractor and the Subcontractor for the work, warranting against defective materials, products, workmanship, water and air
tightness, coatings, installation design, performance and breakage due to defective engineering, fabrication and installation for a period of Ten years shall be submitted by contractor.
14.3
Codes and Standards
In addition to the standards already listed under clause Structural Steel, following standards shall
apply to the works covered by this clause:
DIN
4102
Fire Ratings
BS
476
Fire tests on building materials and structures. Methods for determination

of the fire resistance of non-load bearing
elements of construction
BS
1161
Aluminium alloy sections for structural purposes
BS
1494
Specification for Fixing Accessories for Building Purposes;

Fixings for Sheet, Roof and Wall Coverings
BS
6105
Corrosion resistant stainless steel fasteners
DIN
4108
Thermal insulation in buildings
DIN
4109
Sound insulation in buildings; requirements and testing

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14.4
14.4.1
Wall and Roof Cladding System
The roof and wall cladding shall meet the following performance criteria:
Classification
Physical and Environmental
Test
Humidty Resistance
ASTM D 2247-68
Abrasion Resistance
(falling sand method)
ASTM D 968
Chemical and Environmental
Kesternich Pollution
Resistance Test
DIN 50018
Coating System Integrity Salt Fog

ASTMB 117
Aesthetic
Colour Change and

Fade Resistance Emmaqua
Procedure
Test samples exposes
to 100% relative humidity at 38C for
1000 hours
The test determines
the number of litres of
sand /under controlled conditions) required to abrade
though the samples
coating system exposing bare metal
Samples exposed to
30 test cycles:
each cycle consists of
8 hours at 40C in controlled sulphur dioxide
atmosphere at 100%
relative humidity, followed by 16 hours of
drying at ambient
temperature
Test samples continuously exposed to 5%
salt fog at 35C for
1000 hours. All samples scribed to expose
the underlying metal
before testing. All panels were inspected in
accordance with
ASTMD 714 to evaluate results
Test samples exposed
for minimum of
800,000 Langleys of
solar radiation on
equatorial mount (following the sun) with
reflecting mirrors for
Minimum Test Performance

No effect
375 litres of sand
No blistering
Edge delamination 1-2
mm
No effect
1.89 NBS Unit

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Classification
Test
Procedure
Minimum Test Performance
concentration of sunlight
Eight minutes of water
spray each sunny hour
An exposure of
800,000 Langleys is
equal to approx. 6
years exposure 48 angle in Florida, United
States
The above performance criteria shall be substantiated by test results certified by recognized independent testing authority.
Roof and wall claddings shall normally be constructed of agreed composite wall panels, comprising of
profiled hot dip galvanized steel sheeting in composite insulated (injected rigid foam) panel form. The
foam insulation shall be at least 50 mm thick (PIR) and the internal lining shall match the required
appearance.
Deflection of the roof shall be less than 1/200 of the span, except where roof slopes are below 5 degrees when their limiting deflections shall be 1/300 of the span. Deflection of the wall area shall be
less than 1/150 of the span.
External and internal flashings shall be manufactured from materials matching the external and internal sheeting in gauge, colour and finish.
Fixing of panels shall be done only with high grade (316) stainless steel self tapping screws, complete
with stainless steel (or aluminium) washers incorporating neoprene sealing washers and PVC colour
caps. Screws shall be fixed through the profile crown.
Flashings and side laps shall be fastened with No 14 x 12 stainless steel stitcher screws. Where applicable, black synthetic rubber profile filler blocks shall be used in conjunction with flashings to adequately seal ridge, eaves, gables and drip. This filler block shall be permanently fixed before covering.
All materials and fixing accessories including detailed shop drawings shall be submitted for Employer/Engineer approval.
For fire resistance, sheeting shall comply with BS 476 parts 3, 5, 6, 7 - class 0 or local authorities
requirements whichever is stringent.
14.4.2 Requirements for Walls

External walls are to be constructed that, taking into account the climatic conditions and any air conditioning plant installed in the rooms as well as the manner of use to the rooms, no damp will penetrate
the walls. All external walls must have a minimum sound absorbing index in accordance to DIN 4109
and a heat transmission coefficient acc. to DIN 4108. Appropriate insulation materials will have to be
used to achieve the specified figures.
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The walls shall not allow the passage of rain, moisture, sand or dust into the building. The walls shall
be provided with all necessary horizontal and vertical damp-proof courses and flashings.
All walls and wall panels are to be sufficient strength and thickness in order to withstand superimposed
loads, self-weight and wind pressures without cracking or distortion.
All walls and wall panels shall be adequately secured to allied structural columns and beams.
All walls and wall panels are to be so designed and constructed with expansion joints as to prevent
cracking or distortion through thermal movements. The expansion joints are to be formed with agreed
flexible metal closer strips and/or non-extruding mastic fillers.
All walls and wall panels are all to be free of harmful soluble salts which could form noticeable efflorescence.
14.4.3 Requirements for Roofs

The roof construction is to be such that, with due allowance for the climatic conditions and any air
conditioning plant installed in the rooms, and with the intended use of the rooms taken into account,
no damp will penetrate into the materials used.
All roofs must have a minimum sound absorbing index in acc. to DIN 4109 and a minimum heat transmission coefficient in acc. to DIN-4108 Thermal insulation and energy economy in buildings - Thermal
bridges - Examples for planning and performance.
Appropriate insulation materials will have to be used to achieve the specified figures.
Roof surfaces are to be designed with a min. slope of 5% to the gutters. However roof slope of steel
structures shall be designed considering manufacturer recommendations of roof sheets.
14.5
Panels must be factory manufactured units, produced on a continuous online injection facility with the
bonding foam completely filling the space between the panels. Temperature control of the metal substrates, of the chemical dispensing area and of the online conveyor press is obligatory to maximise the
uniformity of the foam density and the foam substrate adhesion.
The insulation foam shall be a factory injected rigid closed cell fire retardant CFC free, polyisocyanurate
(PIR) foam with a minimum depth of 50 mm between the inner and outer sheets.
The heat transition value U of the panels shall in acc. to DIN 4108
Roof and wall cladding shall provide an acoustic attenuation factor in acc. to DIN 4109
Properties and tests for the insulation foam shall be as follows:

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Property
Test
Test Requirements
Density
ISO 845
40 kg/m3
Compression Strength
ISO 844
C 10 = 1.5 kg/cm2
Modulus Of Compressibility
ISO 844
37 kg/cm2
Tensile Strength
ISO 1926
2.8 kg/cm2
Thermal Conductivity
ISO 2581
0.019 W/m2K
Flame Resistance
ISO 3582
Water Vapour Transmission
ISO 1663
Foam B1 rated minimum or as required by local

authorities.
72 g/m224h(at 38%-90% relative humidity)
Panels shall provide an effective cover width of 1000 mm and shall be manufactured in exact lengths
to suit the structure and minimise jointing. Panels shall have encapsulated side-tapes to ensure maximum side lap joint uniformity.
External steel sheeting shall be of a hot dip galvanized steel sheet (total of both surfaces-G90275 g/m2) of at least 0.75 mm thickness. The external coating system shall be a multi-layer system
consisting of:
Prime Coat: Epoxy primer of a nominal thickness of 8 m.
Base Coat : Two components polyamide cured epoxy, nominal thickness of 100 m
External Weather Coat: Two components polyurethane pigmented colour coat, nominal thickness of
40 m
The inner skin of the panel shall be of hot dip galvanized sheets of at least 0.5 mm thickness, corrosion
protected with a polyester coating of white colour.
Contractor shall propose first class wall/roof metal cladding systems from manufacturer with excellent
reputations for approval by the Employer/Engineer.
14.5.1 Sunshades
Sunshade shall be made of single sheet non-insulated hot dip galvanized steel sheet (total of both
surfaces 275 g/m2) of at least 1.0 mm thickness with trapezoidal profile protected on both sides by a
multi-layer coating system as below:
Prime Coat : Epoxy primer of a nominal thickness of 8 m
Base Coat : Two components polyamide cured epoxy, nominal thickness of 100 m
External Weather Coat: Two components polyurethane pigmented colour coat, nominal thickness of
40 m

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Height of sunshade shall meet the operation and maintenance requirements but not less than 2.20 m.
To improve the shading angle, eaves shall be extended and curved down at least one third of the
height, but shall not affect the personnel movement or maintenance requirements.
14.6
Shop drawings shall be submitted to the Employer/Engineer for his review and acceptance in accordance with the general conditions of contract. The Employer/Engineer approval will not relieve the contractor from his responsibilities under the contract. No work shall be fabricated until the shop drawings, structural calculations and other related submittals, documentation, certification and samples
have been reviewed and approved by the Employer/Engineer. Shop drawings shall incorporate plans,
elevations and sections and full size details of the work covered under this section. The full size details
shall highlight all other materials adjoining the work, their thickness or gauge, areas to be sealed and
sealant material, areas to receive gaskets, tapes, flashings, direction and magnitude of thermal expansion, direction and magnitude of applicable building movement, type of construction including joinery,
fasteners, weld, anchorage assemblies , rainwater goods, sealing of penetrations etc.
Details describing the design, material and installation procedures of anchorage and structural framing
element shall be structurally documented, specified and fully described in the shop drawings.
14.6.1 Supporting Structure

The supporting structure must provide a firm framework for the cladding. All vertical and horizontal
fixing faces should be plumbed and lined, deviations from a true plane being compensated for by packing. At the top and bottom of each elevation there should be a continuous supporting member to
which the edges of the profiles and drip/cap flashing can be firmly attached.
Before commencing fixing ensure that the sheet is correctly aligned at right angles to the ridge and
eaves, and for walls, that sheets are plumb and laps correctly engaged. Ensure that exposed ends of
the sheet line up so that any tolerances on sheet length are accommodated an under laps are not
visible.
Where profiled corner pieces are required the horizontal line must be maintained on adjacent elevations.
14.6.2 Fasteners
Main fasteners (self tapping of self drilling/self tapping screws) are applied to the external side of the
sheet through the centre of every other through, at every purlin, except at the end laps and end of
sheets. Fasteners should be placed in every through at end laps and sheet ends.
All holes should be drilled, not punched, and swarf shall be removed immediately. If left, the swarf will
corrode and the corrosion will stain the coating.
Selection of the correct fastener for each application is important. Fastener of incorrect type size and
material can result in leaks, corrosion and premature failure.

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Unless otherwise stated fasteners are manufactured from plated case hardened steel with a climaseal
or similar protective coating. The fasteners are assembled with twinseal washers made from a combination of EPDM and metal. This generates an effective seal at the sheet surface, around the threads
and under the head of the fastener. Where 19 mm washers are specified they are made from Stainless
Steel. It is essential to ensure that the correct fastener is specified for each application as point design
varies according to the type of structural purlins.

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15
Metal Works /Joiners Work Doors
15.1
15.1.1 General
With regard to thickness of material, sub-construction, stiffening, doors and gates must satisfy the
structural requirements. The fire protection, heat insulation and sound insulation regulations are to
be observed by suitable construction. All security and emergency exit doors to be in accordance with
the Local Safety Regulation.
For fire rated doors, certificates issued by an accredited testing laboratory must be submitted.
The sub-construction must not show any pressure marks on the surfaces; the type of construction used
shall not be liable to warping.
The locks, roses and lock sets must suit the lock cylinders. The cylinders are to be matched to the door
leaf thickness.
Manufacturer of all locking system and ironmongery shall be approved along with his standard guarantees of 5 years for material under this section.
15.1.2 Fire Steel Doors

All insulated steel doors shall provide a fire resistance of two (2) hours and shall be constructed of
inflammable materials in acc. to DIN 4102 and shall be certified by Dubai Civil Deffence. They must be
supplied with all fittings and hardware of SS 316.
Steel doors shall be manufactured in accordance with BS 6510 and proprietary make. Insulation shall
be factory injected over the whole interior area of the door such that no part of the door may become
un-insulated due to shocks, blows or use of the door.
All steel surfaces for doors and frames shall be hot dip galvanized and painted as specified, and the
minimum thickness of the leaf steel sheets shall be 1.5 mm and for frame sheet shall be 2.5 mm. No
joints shall be permitted in the steel sheets. All steel doors shall be of double-skinned construction,
with all necessary reinforcement for hinges, locks and other fixture. The two skins shall be mechanically
interlocked and bonded together to form an envelope, which shall be closed at the top and the bottom
with two steel channels welded to the steel sheets and stiffened by intermediate stiffener.
Minimum single doors leaf shall in general be 1000 mm x 2500 mm, double doors leaf 2000 mm x 2500
mm or as required for equipment transportation. Four steel butt hinges of 140 mm length shall be
provided for\each door leaf. Steel for door frames and shall be fixed to the reinforced concrete or brick
work by agreed anchor bolts M12, passing through holes of 25 mm diameter in the frame. Steel frames
shall be fixed to steel structures and walls by galvanized steel screws and bolts respectively. All door
frames shall be filled with approved shrinkage compensated grouting material.
Steel doors shall be provided with automatic door closer, door selectors at double leafs, built in door
holder, door stopper, panic bars and fitted with fire proof rubber cushions at corners. External doors

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shall have an external weather strip with threshold. Sign plates (name plates) of anodised aluminium
shall be screwed to the door under or above the horizontal bar, on which the self illuminate sign PUSH
BAR TO OPEN is provided. Joints of door frames to walls shall be fire sealed. All accessories and fittings
shall be of SS 316 or higher grade to fit the existing harsh weather conditions and shall be guaranteed
for 5 years for its durability (functionality and corrosion). Fire proof vision panels shall be provided for
all doors leading to escape routes and outside of room/building .
Doors shall be weather-stripped at jambs, heads and meeting stiles of pairs with rubber or neoprene.
Bottom rails of doors shall have a vinyl sweep strip.
Doors shall be accurately fitted to frames. Construction when complete, including glass, shall be capable of withstanding the effect of a 160 km/h wind without deflection greater than 1/300 of the length
of the element. Frames shall be filled with approved grouting material.
The Contractor shall provide the following documents for all steel doors:
Prequalification documents of doors manufacturer who shall be registered by Dubai Civil Defence.
Detailed shop and construction drawings as well as the door schedules
Test certificates proving the conformity of the physical properties and specified fire rating as per relevant standards and regulations.
15.1.3 Roller Shutter Doors

These rolling shutter type doors shall be double skin and thermally insulated acc. to DIN 4108. Roller
shutter doors are to be made of a sandwiched aluminium structure with insulation. They are to be
used only as external doors. The aluminium structure is to be made of highly corrosion resistant aluminium alloys, the surface being coated electrolytically with a heavy aluminium oxide skin capable of
withstanding the climatic conditions. These doors are to be provided with motor drive (commanded
from inside) with roll up and down limit switch ,safety sensors or bollards and dead stop function.
Manual chain extended up to ground level for roller lift device is to be additionally provided. Doors
shall be of size 4.5 m width and 5 m height (minimum) unless otherwise specified in particular specifications or as shown in the drawings. The power supply for the motor and control is to be taken from
the relevant low voltage switchgear.
Construction and installation shall be state of the art and complete with all accessories (top and bottom weather strips, sand and dust brushes along guides, facia sheets,.etc). Single pedestrian steel door
shall be provided beside the roller shutter door for staff access.
The roller for rolling up the door is to be located immediately above and on the inner side of the door
opening. The guides for this door are to be constructed so as to be maintenance free. Manufacturers
shop drawings shall be submitted along with maintenance schedule for Employer/Engineer approval.
All metal guides and rails shall be hot dip galvanized and painted.

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15.1.4 Profile Cylinders

The cylinders are to be of brass, matt nickel-plated, with eight (8) mushroom-headed tumbler pins
below the keyhole, with legally protected profile complete with protection certificate, to guard against
unauthorized entry attempts and duplication of keys. These cylinders should be fitted to any mortice
lock without particular difficulty. They shall be secured by means of a screw from the faceplate. Profile
cylinders shall be used together with round and oval cylinders in the same lock installation.
15.1.5 Master-Key System

An appropriate serviceable and functional master key system for the whole plant shall be installed.
The elaboration of the system itself shall be made in close co-ordination with the Employer and only
after obtaining the Employers approval in writing, the order of production shall be placed. If possible,
the new key system shall be produced matching the existing Master key system of the K- Station.
Generally, the following requirements shall be kept :
The general master key shall operate all locks (25 nos.)
The main key shall open all locks of one main compound (15 nos. per each compound)
The sub-key shall open all locks of a certain group within the main compound (5 nos. per each
group)
The single key shall open the lock of a single room (5 nos. per each door)
Necessary attention shall be paid to later extensions of the master key system, which shall be suitable
for the entire plant including all final stages.
The profile cylinders shall be resistant to the prevailing corrosive atmosphere and shall suit all plant
requirements and shall be of types such as half, double, asymmetrical, short-cylinder, etc. The material
of the cylinders shall be of massive brass, nickel-plated with six security pawl studs.
The keys shall have an engraved indication of the applicable key system and the compound/group/ or
door number.
The Contractor shall provide key cabinets sufficient to store all keys coming with the master key system. All keys shall be labelled with the corresponding door number.
15.1.6 Building and Room Designation Signs

The entrance to each room shall be furnished with following room designation sign type:
Anodised aluminium plate as per Employer/Engineer approval, with specially treated surface, 260 x
100 x 4 mm
Four horizontal grooves, 10 mm wide at the lower end of the plate to take plastic strips with designation printed in English and Arabic language. At the upper portion the room number shall be engraved.

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Fixing: The sign plates shall be screwed to the wall with non-corroding aluminium screws.
Doors between two different rooms shall have two room signs.

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16
Metal Works /Joiners Works Windows and Doors
16.1.1 Aluminium windows

All windows and doors Frames shall be of extruded tubing and profiles used on the exterior shall be
insulated. Windows shall be furnished and erected as required, including all necessary hardware, anchors.
Screws, nuts, washers, bolts, rivets and other miscellaneous fastening devices shall be of stainless
steel. Precautions shall be taken against electrolytic action and other sources of corrosion. Complete
shop drawings and construction details shall be submitted for approval.
Aluminium sections and frames shall be powder coated in accordance with BS 1615 or BS 3987. Their
hardware shall be of concealed construction in the aluminium frame and shall be made of stainless
steel complying with BS 6105. Sections of aluminium extruded sections shall not be less than 50 mm
deep and 2 mm thick.
All windows that can be opened shall be provided with fly screens consisting of a separate aluminium
sub-frame and aluminium fly wire. Fly screens shall be removable for maintenance.
Windows at high levels shall be fitted with agreed mechanical devices allowing for opening from the
ground level.
Marble sills of 30 mm thickness shall be installed under all windows internally (with the exception of
windows in steel cladding). All aluminium windows shall be integrated with double glazed units as
specified.
Joints of window frames to the walls shall be covered with an aluminium angle (20x20) mm on each
side (internally and externally), and they shall be sealed with permanent elastic material in accordance
with the manufacturers instructions. Rubber sealing strips shall be provided at each corner joint of
frames before tightening. Bottom profiles shall be furnished with standard drain holes. All doors shall
be furnished with all accessories and fixtures as specified for steel doors.
For windows fitted in steel structures, special design and details shall be submitted considering the fire
fighting requirements, maintenance, installation and sealing and the architectural view. Fir fixed type
windows, louvers shall be foreseen as part of window construction.
Cavities between window frames and any steel frame construction are to be fully insulated with approved material.
16.1.2 Ventilation louvers

They are to be constructed with an enclosing frame and fixed weatherproof slats. On the inside a bird
guard is to be fitted. Fixing is to be effected as described under clause "Windows". All ventilation louvers shall be equipped with sand and dust trap. Maintenance for the sand and dust traps shall be easily
executed.

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17
Glazing
17.1
All work shall comprise labour, equipment, and the supply of the appurtenant materials and structural
components including transport, loading, off-loading and storage at the site unless otherwise specified. Manufacturer shall provide his standard guarantees for work and material under this section.
17.1.1 Noise levels

Maximum acceptable noise transmission levels for the construction members shall be in accordance
to DIN-4109.
17.2
17.2.1 General
All materials and structural components covered by standards shall meet the quality and dimensional
requirements thereof.
Any glass shall be tempered and glass thicknesses specified shall be deemed as minimum thicknesses
within the allowable tolerance unless another glass thickness is specified. If requested so to do, the
Contractor shall furnish samples and state the names of the suppliers of materials and structural components.
17.2.2 Double Glazing Units

Following properties as the minimum requirements shall be kept
opening size
as per requirements
wind loading
3000 N/m2
type of glazing
double with 12 mm airspace
maximum acceptable noise level
as stated above
type of glass
float 6 mm tempered
light transmittance
0.76
solar radiant heat reflectance
0.12
shading coefficient
0.84
thermal transmittance
1,1 W/m2K

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Above properties shall be verified and confirmed according to the ventilation and heat insulation requirements.
Sealing Compounds
Hardening sealants (putties) shall firmly bond to the glass and the adjacent structural part. They shall
not have any constituents that might adversely affect the adjacent part of the structure of the glass.
They shall not flow; their surface shall be smooth after drying and shall remain unchanged at the expected temperature and humidity conditions.
Permanently plastic sealing compounds (special putties) shall have a good bond to the glass and the
adjoining structural component.
They shall be of adequate compatibility and remain stable at the temperature ranges involved in each
case.
Permanently elastic sealing compounds (surface sealants) shall, at the occurring temperature ranges,
bond to the glass and the adjoining structural member will enough to ensure that with due allowance
for the permissible elongation, they will absorb all movement expansion and shrinkage of the structural components without tearing or breaking off.
They shall withstand atmospheric influences, must not age-harden and shall have adequate compatibility.
17.2.3 Seal Strips

Seal strips shall retain their properties at the occurring temperature range and resist atmospheric influences. They shall be of adequate compatibility.
17.2.4 QA/QC
All materials to be supplied and installed shall be in accordance with the relevant standards and certificates of quality testified by an independent authority or institute shall be submitted to the Employer/Engineer for approval prior to execution of the works.
The Employer/Engineer will make selection of samples for testing material. The Contractor to the
sealed air space not to leak shall give five (5) years guarantee, e.g. when the inside surface starts to
dim and becomes dirty.

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18
Suspended Ceilings
18.1
This specification covers the scope of suspended ceilings that shall be provided as specified for electronic/control rooms, corridors, etc. The Contractor shall submit detail drawings and specification of
the suspended ceiling system before installation of the work.
The suspension system shall be of sufficient strength and rigidity to carry the panels. The panels shall
be secured with locking clips to the grid. The rod hangers shall be made of galvanized steel of 4 mm
diameter (minimum). The joints between the panels and the light fixtures and the air supply shall be
smooth and regular. Power driven fasteners shall be used for fixing the rod hangers in the reinforced
concrete ceiling.
18.2
Material
For all areas where suspended ceiling shall be installed ceiling panels shall be 0.8 mm thick, stove
enamelled, aluminium sheets. In general the size of the panels shall be 600 mm x 600 mm. Panels of
closed appearance of 75 mm or 150 mm wide and length up to 6 meters could also be proposed for
certain areas. Perforated type shall be used for corridors while plain type shall be used for other
rooms/areas.
The panels shall provide the following minimum sound absorption coefficients :
0.45 dB(A) at 500 Hz,
0.70 dB(A) at 1,000 Hz and
0.90 dB(A)at 4,000 Hz
On top of panels rock wool bags shall be laid.
18.3
The Contractor shall be responsible for the integration of the various disciplines (HVAC, lighting, fire
detection, etc.) and shall take into account the location of diffusers and lighting fixtures. Suspension
system supporting the false ceiling panels shall be independent of all services. All services shall be have
its own hanging and supporting structures.
Representative prototypes and mock up samples shall be provided for Employer/Engineer approval.
Those prototypes shall be fitted with all the equipment and components.

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19
Flooring
19.1
This specification covers the scope of flooring works that shall be executed under this contract.. All
work under this division shall comprise all required labour, equipment, and the supply of the appurtenant materials and structural components. Finished floor levels shall be uniform for all areas/rooms at
each level in one building.
All materials and structural components to be supplied and installed by the Contractor and, therefore,
ultimately incorporated in the work shall be new and unused. They shall be suitable for their intended
purpose and appropriately be matched to each other.
All materials and structural components, patterns and colours shall be subject to a review and selection
by the Employer/Engineer.
19.2
Flooring materials shall cover the following:
Bonded cement screed
Raised floor
Tiling works (Refer to Clause 20)
They shall meet the following requirements as specified hereafter.
19.2.1 Bonded Cement Screed

Materials for bonded cement screeds shall consist of Portland cement sand and coarse aggregates as
specified for the relevant location or as instructed by the Employer/Engineer. Mix design and all technical details shall be submitted for approval. Minimum reinforcement or any other form of reinforcement to avoid cracking shall be provided. For mix properties, refer to specified concrete mix of flooring
screed.
19.2.2 Raised Floors

Where indicated on the technical drawings, the Contractor shall furnish and erect removable modular
panels conforming to the following requirements.
19.2.2.1 Material
Composite panels made of high density (700 kg/m3) waterproof chipboard and aluminium sheets for
protection of the interior face. The panel edges shall be slightly chamfered (5) and protected by an
aluminium profile or other conductive material.

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Topping shall be made of high pressure laminate 2.0 mm thick which shall be compatible to suit electrical parameters. Manufacturer shall provide his standard guarantees for work and material under
this section.
Size of the panels

Normal size shall be 600 x 600 mm.
Minimum thickness of the panels 40 mm.
Perforated tiles from same manufacturer and of same dimensions shall be provided as approved for
ventilation purposes.
Loading
5 kN/m2
The maximum allowed deformation shall be 2 mm under 5 kN point load.
Minimum height of the free space between sub-floor and raised floor surface shall be confirmed by
electrical calculations respecting the standard and specified clearances.
Flooring pedestals and stringers shall be zinc plated and shall consist of:
Steel tube of 1 (one and quarter inch) minimum
Base plate of 120 mm x 120 mm x 3 mm
Head cap to be screwed to the steel tube with top plate of 85 mm diameter and 3 mm thickness.
The screw thread on the steel tube shall allow for 40 mm adjustment for unevenness of the ground.
Lock nut shall be provided under the head cap
19.2.2.2 Installation:
The whole system shall be constructed in such a way as to allow conductivity of electrostatic charges
and shall be connected to the earthing system.
Penetrations for cables and pipes shall be arranged with a ready made garment.
Pedestals shall be mechanically fixed to the concrete by 4 screws and further it shall be glued with
epoxy based material.
Floor system shall be rigid and capable to withstand seismic forces. At the perimeter it shall be supported on GI and painted angles fixed to the concrete walls/solid block wall or equipment supports.
Stringers shall be extended and properly connected to edge angles.
Base board or skirting shall be provided to match the floor panels.

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Installation of electrical and instrumentation panels, etc. shall be done on separate supports and
frames, not on top of the computer flooring, thus allowing independent installation of floor. Works
shall be coordinated with cable trays and cable installation to avoid falling of pedestals between cables.
19.3
19.3.1 General
Prior to the start of his operations under this division, the Contractor shall verify that all conditions are
suitable for the timely and effective performance of his work. Work shall be carefully laid out to ensure
symmetry about centrelines of the area involved and to obviate the use of less than half pieces of tiles,
slabs, etc. Floor pedestals shall not fall or clash with cables.
The work shall be executed with the highest degree of precision and according to the drawings and
specifications. Method statements and coordinated shop drawings shall be submitted for all flooring
works. Preparation of Surface
Where no adequately even surface is available for work involving thin beddings, special provisions shall
be made to compensate for this, e.g., rendering coat, screed to the approval of Employer/Engineer.
Any filler or levelling compound shall be applied so that it will bond firmly and durably to the base, will
not crack and will adequately withstand pressure.
19.3.2 Protection of Flooring

All flooring and tiling work, shall be protected from any damage. Flooring access barriers to the individual rooms shall be provided until the floorings can be walked on. Floorings shall be covered by adequate means, such as plastic foils of min. 1 mm thickness with one layer of chip boards on top or
similar protecting materials if other works will be executed in that room after floor laying. Before handing over, all flooring work shall be properly cleaned in acc. to the requirement of the floor material
manufacturer.

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20
Tiling
20.1
Tiling work shall include all required labour, equipment, and the supply of the appurtenant materials
and structural components including off-loading and storage at the site.
Tiling and flooring shall be applied where indicated as per the finish schedule stated on the approved
drawings. All materials and structural components to be supplied and installed by the Contractor shall
be new and unused. They shall be suitable for their intended purpose and appropriately be matched
to each other. Before starting the work, the Contractor shall submit duplicate samples of the patterns
and colours of the material for Employer/ Engineers material approval.
Tiling materials shall cover the followings:
Ceramic tiles minimum 8 mm thick for walls and 12 mm thick for floors supplied with all corner
pieces and base boards
Acid proof tiles minimum 8 mm thick for walls and 12 mm thick for floors supplied with all corner
pieces and base boards
In general, tiles shall have the following properties: sharp, straight, parallel, non-crumbling edges, free
from soluble salt and other detrimental constituents; free from cracks and blisters; rear and side surfaces capable of bonding effectively for placing, laying and jointing.
All tiles shall be of first class quality. Floors which are not covered by tiles shall be properly prepared
and covered by an epoxy screed layer of 6 mm thickness and coated as specified under G.5.5.
20.1.1 Ceramic floor and wall tiles

They shall bear the identification mark of the manufacturer on the lower face in either positive or
negative embossment.
They shall be made from fine-grained vitrified sandstone ceramics of the highest quality. The dimensions of the tiles shall be regular and constant, the upper surface plane, smooth and flawless without
a trace of fissures or blotches. The sides shall be perfectly straight and the corners perfectly rectified.
The shade and hue of the colouring shall be uniform.
They shall give a clear and sound under a hammer stroke. They shall be non-porous, abrasion-resistant
(2.5 mm after 3,000 hours) flexion and shock resistant (250 g/m2).
Acid (hydrochloric, nitric and sulfuric acid) attacks shall be less than 2.5% of their weight and their
water absorbing capacity shall not be in excess of 1.5% of their dry weight. (ref. to DIN 51 102-1 and
DIN 51 102-2 or equivalent standards).
Colour of tiles and colour of bonding will be selected by the Employer/Engineer. Thickness of floor tiles
shall be at least 10 mm.

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20.1.2 Acid-proof Tilling Material

Acid-proof tiles shall be of ceramic material and be scored or dovetailed at the back for improving the
bonding properties and to give a good key. Floor tiles thickness shall be at least 12 mm thick.
The tiles shall be placed into synthetic resin cement such as polyester resin, phenolic resin or furanic
resinand joints shall be applied with acid resistant grout
20.2
Prior to the start construction under this division, the Contractor shall verify that all conditions are
suitable for the timely and effective performance of his work.
Work shall be carefully laid out to ensure symmetry about centrelines of the area involved and to
obviate the use of less than half pieces of tiles, slabs, etc.
The work shall be executed with the highest degree of precision and according to the approved drawings and specifications.
20.2.1 Preparation of Surface

Walls that will receive tiles, shall be prepared to an even surfaces by cement mortar.
The floor surfaces that will receive tiles, screed, etc., shall be cleaned by wet sandblasting and washed
with water under pressure, so as to produce the specified surface condition.
The concrete surface shall be kept thoroughly wet for a period of 24 hours prior to the placing of tiles
etc.
Any filler or levelling compound shall be applied so that it will bond firmly and durably to the base, will
not crack and will adequately withstand pressure.
Prior to placing wall or floor tiles, contractor has to ensure that all embedment (pipes, conduits, etc.)
are completed and fixed in position. Any testing shall be done prior to covering.
20.2.2 Placing
For interior finishing works, all tiles, shall only be set and laid after the fixing of window and door
frames and trims, stop rails, plumbing installations and the application of plaster unless otherwise
specified.
All tiles shall be set or laid plumb, in true alignment and horizontal or at the slope specified, without
any projections, with regard to any specified reference and level lines.
Where floor drains are provided, the plans of the finished floor shall be sloped towards the drains.
Intersections and returns shall be formed accurately. Cutting of tiles, where necessary, shall be done
along the outer edges of the floor and done without marring the tile surfaces. Tiles shall fit closely and
neatly around all plumbing fixtures and around electrical outlets, pipes, fittings etc. so that cover plates

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or escutcheons will overlap the tiles properly. Tiles shall be secured firmly in place and loose tiles/unsound bedding shall be removed and replaced.
Upon completion of the work, all surfaces of ceramic tiles shall be cleaned.

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21
Painting
Refer to Tender Document Volume II, Part G05.5 Corrosion Protection and Painting.
All painting works shall be executed by an approved specialist subcontractor.
The Contractor shall verify that all site conditions are suitable for the timely and effective performance
of his work. Contractor has to protect all finished surfaces from any damages or contaminations.
Samples of all coating systems including the surfaces preparation, texture and colour shall be provided
and approved by Employer/Engineer for further reference. All surfaces shall be smooth and free of any
marks.
Colour of all paintings shall be approved by the Employer/Engineer in accordance to the accepted colour scheme for the project.

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22
Plumbing and Drainage Installation
22.1
General
This specification covers the scope of plumbing and drainage installation work for the buildings where
applicable. The work under this division comprises the design, supply and installation of the complete
plumbing and drainage system s fixtures and shall be carried out in compliance with local rules and
regulations and in accordance with the specifications and drawings defined hereafter.
The Contractor shall prior to commencement of the works, prepare and submit detailed drawings,
indicating the layout and schematic diagram of all piping, fittings and valves, the position of fixtures,
floor drains, , etc. Piping shall be indicated by diameter, slope and invert level.
Outside the building, connection points to general water distribution and drainage system shall be
provided.
The scope also covers external drainage which comprises design, supply and installation of various
kinds of drainage culverts, pipes, and the like, including all accessories such as inspection shafts, etc.
Works shall be completed in all aspects as per Tender Document Volume III, Part P16 Waste Water
System and Sump Pumps.
All work also includes supply, transportation, loading, unloading and storage at Site and placing according to drawings and specification of all materials and components connected therewith.
All earthwork in connection with the work specified hereunder shall be carried out as described under
"Earth Work". Connections of drainage pipes to inspection chambers/pits/manholes or other structures shall be of flexible construction as per DM standard details.
22.2
Materials
All materials and structural components to be supplied, erected, or installed by the Contractor and,
therefore, ultimately incorporated in the work shall be new and unused, and of selected quality approved by the Employer/Engineer.
All materials and accessories for piping, valves, and fittings shall be of the best grade and quality to
suit the requirement. Manufacturer shall provide his standard guarantees for work and material under
this section.
All materials shall be in accordance with ISO, BS, ANSI, DIN or other accepted standards subjected to
approval by Employer/Engineer.
22.2.1 General Requirements

The general requirements for the plumbing and drainage installation works shall be as specified below:
copper pipes with insulation for potable water pipes inside the buildings
UPVC pipes class E for external storm water drainage and sewer lines
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Sanitary fixtures such as specified and shown on approved drawings including all accessories and
fittings.
All outdoor drainage pipes shall be covered with informative/warning tape
22.2.2 Drainage Wares & Fittings

All fixtures specified or shown on approved plans shall be furnished and installed by the Contractor in
a neat and finished manner, making connections with all supply, waste, soil, and vent pipes complete
in every respect, including electrical connections where applicable.
22.2.2.1 Cleaners Sink

The cleaners sink shall be white glazed fire clay heavy duty 445 mm wide with 150 mm high splash
back and bucket grating and PVC pad supplied by an approved manufacturer.
The tap for the cleaners sink and wash basin shall be of approved type meeting the Green Buildings
Regulations.
22.2.2.2 Emergency Shower and Eye Wash

Emergency showers (without shower trays) will be located near the exits inside battery rooms or other
hazardous areas.
The following requirements must be fulfilled:
Flow rate 60 -80 liter/ minute
Stainless steel shower arm with 100 dia shower head
Alternatively wall mounted deluge shower head
Chain stay or push button for automatic release of water flow
Regular floor drain with 150 x 150 stainless steel grating
In battery rooms, acid/chemical resistant eye was and sink/shower shall be provided to the approval
of Employer/Engineer.
22.2.2.3 Regular Floor Drains

All wet rooms shall have floor drains 150 x 150 with stainless steel grating .Number and location of
drains shall be sufficient to clear any surface water/liquids to the main drainage system. In big halls
suitable floor drainage arrangement shall be made by contractor through drain pits and channels with
sufficient floor slopes.
All drains which need to be connected to the neutralization pit shall be acid resistant. Floor drains shall
be of such construction that an accurate and tight connection to the discharge pipe can be achieved.

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22.3
Execution of Work
22.3.1 General
All parts of drainage installations shall be suitably adapted to each other so that the required performance is achieved, safety in operations ensured and corrosion processes largely reduced.
The Contractor shall arrange for any approvals and acceptance required from local authority for the
execution of the works.
All plumbing piping works shall be pressure tested prior to any coverings. All drainage pipes shall be
tested against leakage. All testing works shall be in accordance with international standards and local
authorities requirements.
All water supply and drainage lines shall be connected at interface points (refer to Tender Document
Volume I, Part G03 General Project Requirements). Pressure regulating valve shall be installed for
each building for potable and service waterline at the interface between outside pipelines and inside
building connections.
For external drainage works and prior to laying of pipes, the respective pipe trenches shall be subject
to thorough inspection by the Employer/Engineer with respect to alignment, slope, dimensions and
suitability of bottom to meet the requirements of proper pipe laying.
In general, each pipe trench deeper than 1.25 m shall be secured by means of planks, sheet piling,
struts and bracings, whatever is required according to the soil conditions ground water, nearby roads
and vibration resulting from traffic. The spacing of bracings shall allow mechanical excavation of the
trench where required.
The width of a trench shall not be greater than necessary to permit satisfactory jointing and thorough
tamping of the bedding material under and around the pipe, unless otherwise authorised due to unsuitable material encountered.
22.3.2 Pipes and Fittings

No drainage works or piping shall be made above electrical/equipment rooms. If this cannot be
avoided, installations shall be made with double slab system to the approval of Employer/Engineer.
For water pipes, all pipes including the joints to be insulated at site with ARMAFLEX or other agreed
material in accordance with the appropriate standards.
Where pipes are to run inside concrete structures (mainly slabs and foundations) it shall be designed
and suitable protected to carry all loads and settlement effects and to avoid any damages during concrete pouring. In this case pipes and after complete testing, shall be wrapped with approved protecting
membranes.
Inside building, the main trunk shall be equipped with two isolating valves and one non-return valve.
At least two breather-and-deaerators (air vents) shall be provided at the highest point of the piping.

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All required fittings, such as full-bore valves, non-return valves, angle valves, strainer, discharge taps,
etc., shall be made of red brass, to the approval by the Employer/Engineer.
All exposed parts must be chromium-plated, including tail pipes between angle valve and fixtures.
Pipes passing through floors, walls, ceilings, and partitions shall be run through metal sleeves of the
proper diameter and the annular space between the pipe and the sleeves shall be caulked.
Special equipment, such as pressure gauges, pressure reducing valves, sight glasses, etc. shall be installed in accordance with approved drawings.
Roding eye shall be provided at all bends in the drainage line. Testing and disinfecting of water supply
pipes shall be completed. The whole lines of the drinking water services shall again be drained down,
filled up again and thoroughly flushed through and thereafter filled up and chemically sterilised for a
standing period of not less than 24 hours.
22.3.3 Jointing of Pipes

Jointing of pipes shall be made according to the different types of pipes by solvent-weld, caulked lead,
screwing, welding, flanges, or flexible joints, etc., joints between copper piping shall be by means of
copper-alloy unions.
Care shall be taken to ensure that all piping and fittings are clean internally and free from particles of
sand, soil metal fittings and chips, etc.
22.3.4 Placing of Sanitary Fixtures

When equipment and fixtures are installed, the Contractor shall install such types of fixing devices as
are required to provide for the convenient removal of the equipment and fixtures.
22.3.5 Earthing of Metal Parts

The Contractor shall ensure electrical continuity of all metal fittings and pipeline networks, as installed
by him.

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23
Roads and Pavements, Outdoor Facilities
23.1
This specification covers the scope of roads, walkways and corresponding facilities including gravel
surfacing. Paving and surfacing required for this work includes but is not necessarily limited to supply,
storage and transport of materials, equipment, mixing and placing, all tests, workmanship and finishing
of roads and surfacing. Reinforcing of the exiting access roads at both entries are part of the scope
(Refer to Vender Document Volume III, Part P20 Civil Works)
The actual thickness of road-courses shall be calculated based on the final results of the soil investigation, heaviest loads that will be transported, intensity of traffic, design life. At all paved and asphalted
roads and access entries to buildings 4 PVC sleeves of adequate thickness and diameter not less than
300 mm with concrete surround at maximum every 100 m distance shall be provided.
All road works shall be executed by a specialist company approved by Employer/Engineer.
The followings clauses brief the quality and technical requirements of road construction materials and
surfacing.
23.2
Sub-grade
The area of the Works shall be cleared of any material or obstructions which in the opinion of the
Employer/Engineer might adversely affect the stability of the fill or pavement, and the top layer removed to a depth of 300mm (or more if the design so requires).
The formation shall be compacted to a dry density of at least 95% of the maximum dry density as
determined in BS 1377: Test 13 (BS heavy compaction) and a CBR of 30%.
Tests shall be conducted for each 50 m length of any part of road.
23.3
Sub-Base
Sub-base material shall be crushed rock having suitable properties and confirming to the following
grading:
BS Sieve
mm
75
37.5
10
5
0.6
0.075
Percentage by Weight Passing

100
85 100
45 100
25 85
8 45
1 - 10
When Tested to BS 882 the material shall have a minimum "ten percent fines" value of 5. The material
passing the 0.425 sieve shall have a plasticity index of less than 6.
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The material shall be spread evenly by mechanical means (paving machine or spreader box) on the
preceding material in layers not exceeding 150 mm compacted thicknesses. The minimum thickness
of this layer shall be 150 mm after compaction. The sub-base layer shall be compacted to a dry density
of at least 95% of the maximum dry density and CBR of at least 75 %.
Quality control tests for sub base layer shall be conducted for each 50 m length of any part of road.
Samples of sub base material delivered to the site shall be collected and tested as directed by employer/Engineer at site.
23.4
Wet Mix Road Base
Wet Mix road base material of 150 mm thick shall consist of crushed gravel or crushed rock and shall
be suitably proportioned to confirm to the following grading:
BS Sieve
mm
50
37.5
20
10
5
2.36
0.6
0.075
Percentage by Weight Passing

100
90 100
60 80
40 60
25 40
15 30
8 22
0-8
The fraction passing the 0.075 mm sieve shall not be greater than two-thirds of the fraction passing
the 0.425 mm sieve.
Material constituents shall comply with the following maximum limits:
For material passing the 0.425 mm sieve:
Liquid limit
25%
Linear shrinkage
3%
Plasticity index
6%
For coarse material:
Stone Size Aggregate
50 mm
Aggregate crushing value
25%
Water absorption
2%
Flakiness index
35%

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Elongation index
35%
Mg SO4 soundness
15%
The material shall be spread evenly by mechanical means (paving machine or spreader box) on the
sub-base in layers not exceeding 150 mm compacted thickness. Wet mix shall be mixed by approved
mechanical plant. Water for adjusting the moisture content shall be added at the mixer. After mixing,
the material shall be removed from the mixer and transported to the placing location without delay.
The moisture content at the time of laying shall be within 0.5% of the optimum value determined in
accordance with the Vibrating Hammer Method described in BS 1377, Test 14
The base l shall be compacted to a dry density not less than 98% relative compaction and until movement of the surface ceases and the surface is closed. The completed layer shall have an in-situ CBR of
not less than 90%.
The final surface shall be shaped and finished true to line and level within a tolerance of + 10 mm to
the levels shown on the drawings. Before placing the next construction layer or applying prime coat,
the road base shall be mechanically swept; then cleaned with compressed air to remove loose material. As soon as possible after cleaning of the surface, the road base shall be sealed by the application
of a prime coat as specified.
Quality control tests for sub base layer shall be conducted for each 50 m length of any part of road.
Samples of sub base material delivered to the site shall be collected and tested as directed by employer/Engineer at site.
23.5
Bitumen Macadam Layers General
Aggregate shall be hard, clean, durable crushed rock or gravel, and sand all in accordance with BS 4987.
Laboratory tests shall be made at regular intervals to confirm the suitability of aggregate.
Coarse aggregate is defined as that fraction retained on a 3.5mm BS sieve. It shall have physical properties which do not exceed the following test values when tested in accordance with BS 812:
Wearing Course
Aggregate crusing value
Flakiness index
Elongation index
Water absorption
Base Course
20 25 %
25 30 %
25 30 %
2%
Coarse aggregate may contain up to 15% of pieces with one uncrushed face in each grading size when
tested in accordance with Test Method DM-30l. Aggregate obtained from quarried rock shall be
deemed to satisfy this requirement.
Separate coarse and fine aggregate fractions shall be tested for soundness in accordance with ASTM C
88. After 5 cycles of immersion in magnesium sulfate solution and drying, the loss of weight expressed
as a percentage of the initial weight shall not exceed 12%.

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Any filler, if agreed for use, shall comply with BS 4987 (1973).
The aggregate grading for binder shall comply with the following:
Finished thickness of binder (mm) shall not be less than 60 mm
Wearing course shall be of 40mm minimum finished thickness, the aggregate grading shall be as
follows:
BS Test Sieve
mm
28
20
14
10
6.3
3.35
1.18
0.075
Grading 20 mm nominal size

percentage by weight passing
100
95 100
70 90
55 75
40 60
25 40
15 30
2-
Bitumen shall be of Grade 60/70 penetration with properties corresponding to an interpolation between Grade 50 and Grade 70 as defined in BS 3690. The specific gravity and temperature/viscosity
relationship shall be provided.
The frequency of testing of the penetration index shall be two tests per delivery of bitumen. The PI
range shall be -1 to +1.
Quality control tests for bitumen layers (after completion) shall be conducted for each 50 m length of
any part of road. Samples of mixed materials delivered to the site shall be collected and tested on daily
basis and as directed by employer/Engineer at site.
23.5.1 Design of Bitumen Macadam Layers

Design mixes shall be submitted for approval and proved by means of laboratory, plant and field trials.
Tracking tests may also be required.
The mixes shall be tested in accordance with the following methods:
Preparation and testing of Marshall Specimens: ASTM D 1559 using 75 blows per face.
Bulk Specific Gravity of specimens: ASTM C 1188.
The values for specific gravities of the aggregates to be used in calculating the voids shall be taken as
the mean of the Bulk, Apparent and Effective Specific Gravities as defined in the American Asphalt
Institute publication "Mix Design Methods for Asphaltic Concrete."

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The adhesion of bitumen to aggregate shall be proven by comparing the stability of specimens cured
in water and air for eight days at 18 degrees C. The ratio of stability in the two shall not be less than
0.65.
Wearing course mix shall be subjected to further Marshall tests at 80 degrees C after oven heating for
a period of 2 hours; the stability/flow ratio shall not fall below 270 at this temperature.
Mixes with a bitumen content corresponding to the maximum allowable for the selected job mix shall
be compacted to refusal, or to 600 blows per face whichever shall be reached first, and the resulting
voids-in-mix values shall be not less than 3%.
The designed mixes shall comply with the following:
Binder
Wearing
Course
Course
Voids in mix
7 - 10
5-8
Voids in mixed aggregate %
14 - 20
14 -20
Minimum stability (kg) 750
1000
Flow (mm)
2-4
2-4
Minimum stability flow ratio (kg/niTn)
270
320
Bitumen content (% of total mix)
3.3 4.0 3.5 4.2
Voids filled with Bitumen (%)
48 - 60
48- 60
After a design mix has been agreed and adopted as a job mix, the maximum permitted deviations from
the job mix shall be as follows:
Permitted Deviations:
Sieve size:
6.3 mm or larger
5%
3.35 mm
4%
0.6 mm to 1.18mm
3%
0.075mm to 0.3mm
2%
Smaller than 0.075mm 1%
Bitumen
0.2%
Voids in mix
1%

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The application of the above deviation percentages shall not result in values falling outside those specified in the clause covering the design and testing of bitumen macadam mixes.
Chlorides and Sulphates shall comply with clause 23.6.
23.5.2 Mixing and Placing of Bitumen Macadam Layers

The mixing and placing of bitumen macadam shall be carried out in accordance with the requirements
of BS 4987 (1973).
Bitumen and aggregates shall not be heated to above 150C and 170C, respectively, and the temperature difference between them at the time of mixing shall not exceed 15C. The mixing temperature
shall be established from the bitumen viscosity/temperature graph in accordance with ASTM D2170
and ASTM D1559. Agreed facilities for continuous measurement of temperatures shall be provided.
Heat loss shall be minimized during transit and the macadam shall not be discharged into the paver at
a temperature less than 120 degrees C.
Bitumen macadam shall generally be spread, leveled and tamped by agreed self-propelled pavers.
Immediately after arrival at the site, the macadam shall be supplied continuously to the paver and
placed without delay. The rate of the delivery of material to the paver shall be regulated so that the
paver may operate continuously and it shall be adjusted to provide an even and uniform flow of material across the full laving width, freedom from dragging or tearing of the material and minimum segregation.
Excess material arising from placing base course shall be removed by brooming or light raking. Overraking causing segregation of the material shall not occur. The excess shall be discarded and not used
elsewhere.
After placing, the macadam layers shall be compacted to the thickness shown on the Drawings by
rolling to a density of not less than 98% of the maximum density of the agreed daily Marshall laboratory
density.
A priming coat of grade MC 30 petroleum bitumen shall be applied to the road base at the rate of 0.55
to 0.7 liter per m2, before placing macadam. The binder course, shall not be laid until the priming coat
has been cured.
A tack coat of grade MC 30 cut-back bitumen or SS1H emulsion shall be applied to the binder course
at the rate of 0.25 to 0.35 liter per m2 before placing, the wearing course. The wearing course shall
not be laid until the tack coat has cured. The wearing, course shall adhere satisfactorily to the base
course.
The required levels of base course and wearing course shall be determined from the finished road
surfaces calculated from the vertical profiles and the cross falls shown on the drawings. The permitted
vertical deviation from the true level of any point shall be 5mm for base course and 3mm for wearing course.

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The thickness of the individual layers of base course and wearing course shall not vary by more than
5 mm from the theoretical thickness of the respective layers.
The combined thickness of binding course and wearing course layers shall not vary from the theoretical
combined thickness by more than 10% of that thickness, or by 10mm, whichever is less.
Core samples shall be collected from site at least (one core every 75 m of any part of road) and tested
to verify the degree of compaction and thickness
Traffic shall not be allowed to run on any surfaces without approval.
23.6
Chlorides and Sulphates
The level of the acid-soluble chloride (as NaCI) (BS 812: Part 117) in the sub-base and road-base layers
shall not exceed 3.5% and 0.5% by weight respectively.
The level of acid-soluble sulphate (as SO3) (BS 812: Part 118) in the sub-base and road-base raiders
shall not exceed 2.0% and 0.5% by weight respectively.
Potable water shall be used for compaction purposes.
23.7
Hard Shoulders
The material used for any hard shoulders shall comply with the specification for wet-mix road base.
23.8
Testing of Material, Field Tests
All materials involved in road construction shall be tested upon delivery to the site to verify its compliance with specifications.
Field tests as CBR, compaction of road layers, coring for asphalt layers and verifying marshal properties,
physical and mechanical properties of aggregates etc. shall be conducted as specified above and as per
sequence approved by Employer/Engineer. All testing shall be conducted by approved third party laboratory. For asphalt materials and coring testing shall be carried out by DCL.
23.9
Jointing New to Existing Pavement
Where new pavement is required to join into existing road construction, the joint shall be formed and
treated in accordance with the drawings.
Unless shown otherwise on the drawings, each layer of existing bituminous course shall be cut back to
a clean vertical face and coated with hot bitumen of a grade suitable for the purpose immediately
before laying adjacent new bituminous material.

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23.10 Fencing and Gates

The work pertaining under this Clause shall include the provision of all materials required for the construction and erection/installation of fencing works around fuel gas system area and other areas where
access is restricted according to the approved design and arrangement drawings. ,
All fence and gates posts and struts shall be anchored in rigid concrete RC foundations of grade C 25,
reaching at least 80 cm below and 10 cm above ground. Concrete mixes and materials shall be as specified under the concrete section of this specification. In the vicinity of gates, adequate provisions to fix
the fences shall be provided.
All fencing, gates, doors, etc., have to be properly connected to an earthing system.
All fencing shall have at least 40 cm (30 cm in ground) encasement below in the continuous reinforced
concrete beam, minimum width 20 cm. The distance of the bottom of the wire mesh to the levelled
ground surface shall not exceed 5 cm, which means 5cm of fence is to be embedded in to the concrete.
All fixing accessories shall be of SS 316.The Contractor shall furnish an approved manufacturer's guarantee on all fencing materials, covering a period of five years.
23.10.1 Steel Fencing Posts

The posts for fencing shall be of high grade steel of tubular or conical triangular hollow sections, filled
in with concrete C 20 and of the required size and shape. The posts shall be hot dip galvanised internally
and externally and PVC coated. Before hot-dip galvanising of the posts, strong T-shaped flanges to
receive fixing brackets shall be welded.
Corner posts shall be equipped with corner turnbuckles for bracing wires and with joint clamps for
horizontal bracing rails and reverse bracing. All components shall be plastic-coated to meet a double-corrosion protection.
Application: As shown on approved drawings. Security fences, overall height about 2.5 m .Posts shall
not be more than 3.0 m apart.
23.10.2 Chain Link Wire-Mesh

he chain link wire-mesh shall be of minimum 3 mm diameter, opening size of min: 50 x 50 mm, from
standard and first class manufacture, hot-dip galvanised and provided with plastic coating, colour to
the discretion of the Employer/Engineer.
23.10.3 Gates
Gate frames are to be hollow steel sections according to the requirements of the design. The gates
shall be fitted with adjustable hinges and bronze bushes with greasing points. The in-fill of the gates
shall be of chain link wire mesh or tubular sections to the approval of Employer/Engineer. The gates
shall be lockable and the drop-bolts of inactive leafs shall be locked in the closed position by the active
gate to prevent opening.

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All gate leafs shall be connected to the earthing system of the fence through the gate posts.
23.11 Landscaping
The Work includes supply and placement of gravel as specified below.
23.11.1 Products and Material (NOT APPLICABLE)

23.11.1.1
Topsoil (NOT APPLICABLE)
23.11.1.2
Planting Mixture (NOT APPLICABLE)
23.11.1.3
Gravel
Gravel will be 20 mm uniform sized crushed rock. Quality specification shall be as in the Clause Concrete and Reinforced Concrete- Aggregates. Thickness of gravel layer shall be 10 cm and the top level
shall flash with the surrounding walkways or curb stones.
Gravel shall be distributed evenly at the areas specified. Material shall be brought to the area of placing
in quantities required for that portion of work only. Excessive dust shall be avoided during unloading
of the material and the passage for the other contractor to their working areas shall not be blocked by
the dumped material.
Before laying of gravel the subsoil shall be tamped so that it would not mix with the gravel placed.
23.11.1.4
Execution of Work (NOT APPLICABLE)
23.11.1.5
Trees and Shrubs (NOT APPLICABLE)
23.12 Interlocking Paving Blocks

Roads and areas to be paved with interlocking concrete blocks shall be excavated and placed with 300
mm depth of compacted road base material at the exact levels and falls required for the finished work.
If parts of the base are found to be unstable the Contractor shall excavate further to a firm bed and fill
with layers of fine crushed rock or aggregate, thoroughly compacted. The upper surface of the base
shall reflect the exact profile, fall or contour of the final paving as irregularities shall not be compensated for by varying the depth of sand bedding.
Compaction of formation and base for interlocking paving blocks shall be as per road layers.
A stable edge shall be provided to retain the paving units and sand bedding by means of precast concrete edging unit or kerbs set in-situ concrete.
The sand bedding shall be a fine, well graded sand in a dry to moist condition and laid to an un compacted thickness of 50 mm over a layer of polythene sheet or any moisture barrier material. Finished
interlock pavement shall be covered with a layer of dune sand and vibrated/compacted to achieve the
maximum interlocking and fill all voids.

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Samples of the paving blocks are to be submitted to the Employer/Engineer for his approval. No orders
shall be placed with the manufacturers until the Employer/Engineer's approval has been given.
The mix for paving blocks shall contain a water repelling additive.
The paving blocks shall be laid in accordance with the manufacturers instructions and shall be compacted at completion of each day's work.
The interlocking block shall be a minimum of 100 mm thick for traffic areas and 60 mm thick for walkways and foot paths. Concrete quality must be approved by the Employer/Engineer.
23.13 Kerbs
Kerbs, channels, edgings and quadrants shall be cast generally to BS 140 but to the dimensions shown
on the drawings where these differ from preferred dimensions list in BS 340. They shall be cast to the
required road bending curve/radius. In general kerbs shall be 200 mm thick and 300 mm in depth and
shall be laid with a 6 mm gap and pointed with I to 3 polymer modified cement mortar above road
level only. Concrete bedding and backing to kerbs shall be cast in-situ to the dimensions shown on the
drawings and as per Dubai Municipality details.
Flush kerbs shall be similarly laid and jointed or may be cast in-situ. The outside comer of the kerbs
shall be chambered.
In the case of precast kerbs one joint in ten shall be left unpainted and 6 mm compressible insert
provided, and a construction joint formed in the haunching at this point for expansion. Similarly expansion joints are to be formed in in-situ kerbs at 4.0 in intervals.
All raised kerbs shall be alternately painted black and white in the plant area and at junctions.
23.14 Traffic Signs

Traffic signs for all roads shall be reflectorised and shall be provided as per local rules and regulations.
The signs and their individual elements shall be capable of withstanding the maximum wind pressure
referred to in the design requirements. Layout drawings showing number, type and position of signs
shall be submitted for approval. Traffic mirrors shall be provided at road junctions and as directed by
Employer/Engineer.
Mounting posts shall be of circular hollow steel section structural steel, Grade 43 to BS 4360. Posts
shall be jointed with bolts at the base (150 mm above the finished level- socket type). The post heads
inserted in concrete foundations shall be sealed all around to prevent the ingress of water. All foundation works shall have minimum reinforcement and shall be protected by two coats of coal tar
Where there is a possibility of aluminium and steel coming into contact with each other at fixing points
a suitable non-degradable inert packing shall be provided to prevent such contact.

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All steelwork shall be hot-dip galvanised to BS 729 and shop painted according to Tender Document
Volume II, Part G05.5 Corrosion Protection and Painting the finishing colour coats being according
to the Local Traffic Authority requirements.
23.15 Carriageway Markings

The material for markings shall be hot applied Spray-plastic complying to the requirements of
BS 3262, approved for use in the tropics.
Carriageway markings shall only be applied to surfaces which are clean and dry. Where owing to the
action of traffic or otherwise, the pavement has become polished before the application of road markings, at the direction of the Employer/Engineer a tack coat compatible with the marking material shall
be applied in accordance with the manufacturers instructions. Markings shall be free from raggedness
at their edges and shall be uniform and free from streaks.
Ballotini is to be incorporated at 18% to 22% by weight of total mix and also to be applied to the
surface of the markings at the rate of 400 to 500 g/m2.
The laid thickness of the markings shall be minimum 2 mm.
The Contractor shall state the maximum safe heating temperature, the temperature range of the apparatus and the method of laying to be used.
Road marking details shall be submitted for approval.
23.16 Guard Rails

Guard rails shall be provided where the occupants of a vehicle or passers-by can be endangered by a
vehicle leaving the road.
Standard profiles of guard rails (W section) are to be used also to protect pipes and structures located
at traffic areas and be designed to withstand impact forces in accordance to the traffic type and speed.
Railings shall be of galvanized steel which shall be epoxy-painted in addition.. Layout drawings and
details shall be submitted for approval.
23.17 Temporary Traffic Signs and Carriageway Markings

For road diversions, the signs and markings shall generally follow the specification for permanent
works.
Posts and foundations shall be designed to facilitate re-use but also must be robust.
Warning lights, heavy duty bollards, etc., are to be provided.
All diversion works and the location, quantity and specification for all signs, lights, bollards etc., are to
be agreed by the local Authorities and the Traffic Police Department.

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Jebel Ali Power Station ‘K’ Phase III Civil Works RFx No. 2131600023

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Jebel Ali Power Station ‘K’ Phase III Civil Works RFx No. 2131600023

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Dubai Electricity and Water Authority

RFx No.: 2131600023

Issue and Revision Record

Volume II, Part G05.4

Scope of Work, Completeness .................................................................................... 7

Civil Design/Engineering ............................................................................................. 7

Codes and Standards .................................................................................................. 7

American Standards: .................................................................................................. 7

European Standards: .................................................................................................. 8

Local Standards and Regulations ................................................................................ 8

Design Criteria for Layout, Arrangement, Drawings, Execution ................................. 9

Basic Requirements for All Civil Works....................................................................... 9

Design Loads / Load Assumptions ............................................................................ 11

Special Requirements for Materials To Avoid Corrosion Problems Reinforced

Special Requirements for Materials to Avoid Corrosion Problems Steel

Materials (Quality, Delivery, Storage, Handling) ...................................................... 17

New /Unused Materials ............................................................................................ 17

Supplier/ Material Approval Procedure ................................................................... 18

Site Installation and Demobilisation ......................................................................... 19

Scope of Work, Completeness .................................................................................. 19

Execution (Assembling, Installation) ........................................................................ 19

Site Supervision/Survey/Investigations .................................................................... 20

Site Supervision: ....................................................................................................... 20

Survey and Investigations ......................................................................................... 21

Dewatering During Construction .............................................................................. 22

Site Clearance and Earth Work ................................................................................. 24

Site Clearance- General ............................................................................................ 24

Earth Works, Completeness ..................................................................................... 24

Materials (Quality, Delivery, Storage, Handling) ...................................................... 25

Select Fill ................................................................................................................... 25

Ordinary Fill .............................................................................................................. 25

Special fill .................................................................................................................. 25

Execution (Assembling, Installation) ........................................................................ 25

Jebel Ali Power Station K Phase III

Volume II, Part G05.4

Stockpiles and Disposal ............................................................................................ 26

Preparation of Foundations ...................................................................................... 26

Soil Replacement ...................................................................................................... 27

Pipe Bed Preparation ................................................................................................ 27

Protection of Existing Utilities and Services ............................................................. 27

Deep Vibratory Techniques ...................................................................................... 28

Dust Control .............................................................................................................. 28

QA/QC, Test and properties ..................................................................................... 28

Quality Assurance for Vibro Techniques .................................................................. 29

Piling Works .............................................................................................................. 30

Documents to Be Submitted .................................................................................... 30

Design Criteria, Arrangement Drawings ................................................................... 30

Bored Cast-In-Place Piles and Driven Piles ............................................................... 30

Materials (Quality, Delivery, Storage, Handling) ...................................................... 31

Steel Reinforcement and Concrete .......................................................................... 31

Execution (Assembling, Installation) ........................................................................ 32

Working Platform ..................................................................................................... 32

Piling Record ............................................................................................................. 33

Test Piles, Static Loading Tests ................................................................................. 34

Concrete Work .......................................................................................................... 36

Scope of Work, Completeness .................................................................................. 36

Civil Design/Engineering ........................................................................................... 36

Dimensional tolerances ............................................................................................ 36

Concrete with Special Properties ............................................................................. 36

Finishing Of Concrete Surfaces ................................................................................. 38

Bar-bending Schedules ............................................................................................. 38