construction handbook lastest ver 24april09 english general

8/2/2019 Construction Handbook Lastest Ver 24April09 English General

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CONSTRUCTION HANDBOOKRADIO ACCESS NODES AND BTS SITES

Document type : Construction Hand-BookDocument number : SL NI SE ID/CW/HB-2009/007Creator : Werner TonModified : Operation Support Team LeaderReviewer : CME ManagersApprover : Ishak HalimDate approved : April 2009Function : NI/SE Indonesia


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Type of Document Guidelines - Number Revision

SL NI SE ID/CW/HB-2009/007 00CME HAND BOOK

Page 2 of 133 Date April 2009

TittleNetwork ImplementationSite Engineering CW

Civil Mechanical Electrical Hand-Book

TABLE OF CONTENTS

1. INTRODUCTION ......................................................................................................................... 112. Remote BSC / RNC and Major SDH Sites................................................................................... 113. Site Engineering........................................................................................................................... 12

3.1 Site Supervision..................................................................................................................... 123.2 Access and Use of Site ......................................................................................................... 123.3 Site Cleanliness..................................................................................................................... 123.4 Site Facilities ......................................................................................................................... 123.5 Setting Out and Drawings...................................................................................................... 123.6 Security.................................................................................................................................. 133.7 Technical Site Survey............................................................................................................ 143.8 Detailed Site Design (Greenfield Site)................................................................................... 143.9 Soil Investigation ................................................................................................................... 14

3.10 Existing Tower Evaluation (Greenfield Site) ...................................................................... 143.11 Static Calculations for Existing Building............................................................................. 153.12 Detailed Design Package................................................................................................... 163.13 Tower Foundations ............................................................................................................ 17

3.13.1 Standard Tower Foundation Designs ......................................................................... 173.13.2 Site Specific Foundation Design................................................................................. 17

3.14 As Built Drawings............................................................................................................... 174. Construction................................................................................................................................. 18

4.1 Quality Gates for Construction Works (CW).......................................................................... 184.2 Kick Off Meeting .................................................................................................................... 184.3 Site Clearing and Demolition................................................................................................. 194.4 Bored Piling ........................................................................................................................... 20

4.4.1 General........................................................................................................................... 204.4.2 Setting Out ..................................................................................................................... 204.4.3 Equipment and Personnel.............................................................................................. 204.4.4 Rejected Piles ................................................................................................................ 204.4.5 Records.......................................................................................................................... 214.4.6 Concrete......................................................................................................................... 214.4.7 Excavation...................................................................................................................... 214.4.8 Placement of Reinforcement .......................................................................................... 224.4.9 Concreting of bore Piles................................................................................................. 234.4.10 Cutting Back of Bore Piles .......................................................................................... 244.4.11 Integrity Testing .......................................................................................................... 254.4.12

Piling Records............................................................................................................. 26

4.4.13 Excavations ................................................................................................................ 284.4.13.1 Sheet Piling................................................................................................................. 294.4.13.2 Dewatering (Wellpoint Dewatering) ............................................................................ 304.4.14 Reinforcement ............................................................................................................ 314.4.15 Concrete Works.......................................................................................................... 324.4.16 Concrete Material ....................................................................................................... 324.4.17 Use of Admixtures in Concrete................................................................................... 334.4.18 Concrete Transportation and Placement.................................................................... 334.4.19 Formwork.................................................................................................................... 344.4.20 Construction Joints (Cold Joints) ................................................................................ 344.4.21 Repair of Concrete...................................................................................................... 37

4.4.22 Testing of Concrete .................................................................................................... 384.4.23 Failure of Concrete Tests ........................................................................................... 404.4.23.1 Honeycomb................................................................................................................. 404.4.23.2 Honeycomb Repair Process....................................................................................... 414.4.24 Daily Records ............................................................................................................. 42


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4.4.25 Backfilling.................................................................................................................... 424.5 Tower and Monopole Fabrication, Delivery, Collection, Delivery, Erection and Painting ...... 45

4.5.1 Fabrication and Storage................................................................................................. 454.5.2 Collection........................................................................................................................ 464.5.3 Delivery of Towers and Monopoles................................................................................ 474.5.4 Erection of Towers and Monopoles................................................................................ 484.5.5 Horizontal Feeder Tray................................................................................................... 524.5.6 Painting of Towers and Monopoles................................................................................ 534.5.7 Tower Identity Plate........................................................................................................ 54

4.6 SHELTER OR OUTDOOR EQUIPMENT FOUNDATION..................................................... 544.6.1 Standard Foundation Designs........................................................................................ 544.6.2 Site Specific Shelter or Outdoor Equipment Foundation Designs.................................. 554.6.3 Installation of Shelter or Outdoor Equipment Foundation .............................................. 554.6.4 Sun Shelter (outdoor equipment) ................................................................................... 55

4.7 BTS Baseframe ..................................................................................................................... 564.8 PISM...................................................................................................................................... 564.9 Other Structures and Equipment........................................................................................... 57

4.9.1 Retaining Walls .............................................................................................................. 574.9.1.1 Design......................................................................................................................... 57

4.10 Access Roads.................................................................................................................... 574.10.1 Requirements ............................................................................................................. 57

4.11 Gensets and Foundations.................................................................................................. 584.11.1 Requirements ............................................................................................................. 584.11.2 Genset Foundation Design......................................................................................... 594.11.3 Genset Installation...................................................................................................... 60

4.12 COMPOUND FENCE / WALL and GATE.......................................................................... 61

4.12.1 Fence / Wall Types and Dimensions .......................................................................... 614.12.2 Fence / Wall Foundations........................................................................................... 624.12.3 BRC or Steel Defensive Fence Construction.............................................................. 624.12.3.1 Posts........................................................................................................................... 624.12.3.2 Panels......................................................................................................................... 624.12.3.3 Gate............................................................................................................................ 634.12.3.4 Barbed Wire................................................................................................................ 634.12.3.5 Fence Quality.............................................................................................................. 634.12.4 Brick Wall.................................................................................................................... 644.12.4.1 General....................................................................................................................... 644.12.4.2 Brickwork .................................................................................................................... 644.12.4.3

Rendering ................................................................................................................... 65

4.12.4.4 Painting....................................................................................................................... 664.12.4.5 Wall Quality................................................................................................................. 66

4.13 COMPOUND FINISHING .................................................................................................. 674.13.1 Objective..................................................................................................................... 674.13.2 Surface Finish............................................................................................................. 674.13.3 Compound Lighting..................................................................................................... 68

4.14 ROOFTOP PREPARATION .............................................................................................. 694.14.1 Design and General Objectives.................................................................................. 694.14.2 Load Connections....................................................................................................... 704.14.3 Self Standing Poles .................................................................................................... 724.14.4 Cable Management .................................................................................................... 73

4.14.5 Access and Safety Equipment.................................................................................... 734.15 AVIATION WARNING LIGHTS.......................................................................................... 744.15.1 General Requirement ................................................................................................. 744.15.2 Control ........................................................................................................................ 744.15.3 Installation................................................................................................................... 75


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5. FLAT PACK SHELTER (CKD)..................................................................................................... 765.1 General.................................................................................................................................. 76

5.2 Wall Construction .................................................................................................................. 775.3 Roof Construction.................................................................................................................. 775.4 Floor Construction ................................................................................................................. 785.5 Door Construction and Accessories ...................................................................................... 795.6 Installation ............................................................................................................................. 80

6. EQUIPMENT ROOMS................................................................................................................. 816.1 General.................................................................................................................................. 816.2 Walls...................................................................................................................................... 816.3 Partition Walls........................................................................................................................ 826.4 Exterior Walls ........................................................................................................................ 826.5 Floors..................................................................................................................................... 826.6 Roof / Ceiling......................................................................................................................... 82

6.7 Door....................................................................................................................................... 836.8 Wall Penetrations .................................................................................................................. 836.9 Interior Finishing.................................................................................................................... 836.10 Exterior Finishing ............................................................................................................... 84

7. SHELTER or EQUIPMENT ROOM MECHANICAL & ELECTRICAL EQUIPMENT .................... 857.1 General.................................................................................................................................. 857.2 Cable Ladder System............................................................................................................ 85

7.2.1 General........................................................................................................................... 857.2.2 Layout in Shelters........................................................................................................... 867.2.3 Layout in Equipment Rooms .......................................................................................... 867.2.4 Vertical Runs.................................................................................................................. 867.2.5 Materials......................................................................................................................... 87

7.2.6 Installation ...................................................................................................................... 877.3 Cable Glands......................................................................................................................... 877.4 ACPDB (Sub Distribution Panel) ........................................................................................... 887.5 Air Conditioning ..................................................................................................................... 90

7.5.1 General........................................................................................................................... 907.5.2 Installation ...................................................................................................................... 917.5.3 Controls.......................................................................................................................... 92

7.6 External Alarm System.......................................................................................................... 937.6.1 General Requirements and Objectives .......................................................................... 937.6.2 Fire Alarm....................................................................................................................... 937.6.3 Intruder Alarm................................................................................................................. 937.6.4

AC Power Alarm............................................................................................................. 93

7.6.5 Air Condition Failure....................................................................................................... 947.6.6 Aircraft Warning Light Power Failure.............................................................................. 947.6.7 Lightning Arrestor Failure............................................................................................... 947.6.8 Outdoor AC tamper alarm .............................................................................................. 94

7.7 Emergency Exhaust Fan ....................................................................................................... 947.8 Internal Lighting and Utilities ................................................................................................. 947.9 Portable Fire Extinguisher ..................................................................................................... 957.10 Electrical Equipment and Cable Installation....................................................................... 95

8. EARTHING AND LIGHTNING PROTECTION............................................................................. 968.1 General Requirements .......................................................................................................... 96

8.1.1 Objectives....................................................................................................................... 96

8.1.2 Ground Resistance......................................................................................................... 968.1.3 Connection to Existing System....................................................................................... 968.1.4 Protection Area............................................................................................................... 968.1.5 Line of Strike .................................................................................................................. 96

8.2 External Earthing and Lightning Protection System. ............................................................. 97


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8.2.1 Air Terminals .................................................................................................................. 978.2.2 Lightning Down Conductor............................................................................................. 97

8.2.3 Down Conductor Pit ....................................................................................................... 988.2.4 Feeder Earth Bars .......................................................................................................... 998.2.5 Under Ground Dissipation System (Greenfield Sites) .................................................. 1018.2.6 Under Ground Dissipation System (Rooftop Sites) ...................................................... 1018.2.7 Earth Control Pit ........................................................................................................... 1028.2.8 Connections to Dissipation System (Greenfield Sites)................................................. 1038.2.9 Connection to Dissipation System for Rooftop Sites.................................................... 1058.2.10 Labelling of External Earthing and Lightning Protection System. ............................. 106

8.3 Internal Earthing System ..................................................................................................... 1068.3.1 Equipment Room / Shelter Earthting Bar ..................................................................... 1068.3.2 Feeder Entry Earthing Bar............................................................................................ 1068.3.3 Connection to Equipment Room Earthing Bar ............................................................. 107

8.3.4 Labelling of Internal Earth Cables ................................................................................ 1078.3.5 Best Practice Grounding Installation ............................................................................ 107

9. POWER APPLICATION, CONNECTION and KWH METER PANEL........................................ 1089.1 Project Management ........................................................................................................... 1089.2 Application for Power Connection ....................................................................................... 1089.3 Installation of the Power Connection................................................................................... 1089.4 KWH Meter Panel and Box.................................................................................................. 1099.5 Installation of the Power Connection................................................................................... 111

10. Sub-contractor Self-Assessment ......................................................................................... 11111. Acceptance Test Procedure (NSN - Sub-contractor) .......................................................... 11212. Acceptance Test Procedure (Customer - NSN) .................................................................. 112


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FIGURES

Figure 1 Safety Sign ...................................................................................................................... 13Figure 2 Safet Fence ..................................................................................................................... 13Figure 3 Safety fence..................................................................................................................... 13Figure 4 Technical Site Survey Figure 5 Soil Test Record ........................................... 14Figure 6 Soil Investigation on Site ................................................................................................. 14Figure 7 Soil Investigation on Site ................................................................................................. 14Figure 8 Soil Investigation on Site ................................................................................................. 14Figure 9 SDA Template ................................................................................................................. 15Figure 10 Re-bound Hammer Test ................................................................................................ 15Figure 11 Re-bound Hammer Test ................................................................................................ 15Figure 12 Re-bound Hammer Test ................................................................................................ 15

Figure 13 Kick-off Meeting Template............................................................................................. 18Figure 14 Site Location clearly stacked out ................................................................................... 18Figure 15 Site Location clearly stacked out ................................................................................... 19Figure 16 Site Location cleared from Vegetation and Debris ........................................................ 19Figure 17 Site location cleared ready for Excavation.................................................................... 19Figure 18 Bore Pile equipment ...................................................................................................... 20Figure 19 Bore Pile equipment ...................................................................................................... 20Figure 20 Bore Pile equipment ...................................................................................................... 20Figure 21 Bore pile equipment....................................................................................................... 20Figure 22 Land preparation for Bore Piling.................................................................................... 21Figure 23 Bore pile rebar cage ...................................................................................................... 22Figure 24 Tremie equipment.......................................................................................................... 23

Figure 25 Cutting back of bore piles .............................................................................................. 24Figure 26 Cutting back of bore piles .............................................................................................. 24Figure 27 Integrity testing .............................................................................................................. 25Figure 28 Integrity testing .............................................................................................................. 25Figure 29 Integrity testing .............................................................................................................. 25Figure 30 Piling record template.................................................................................................... 26Figure 31 Excavated foundation / safe storage of excavated material .......................................... 28Figure 32 Sheet Piling.................................................................................................................... 29Figure 33 Sheet Piling.................................................................................................................... 29Figure 34 Wellpoint Dewatering..................................................................................................... 30Figure 35 Surface Dewatering Pump............................................................................................. 30Figure 36 Submersible Dewatering Pump ..................................................................................... 30

Figure 37 Rebar bending setup ..................................................................................................... 31Figure 38 Rebar setup ................................................................................................................... 31Figure 39 Spacer preparation........................................................................................................ 31Figure 40 Storage of aggregates................................................................................................... 32Figure 41 Site mix approval process.............................................................................................. 32Figure 42 Pre-mix in Bags ............................................................................................................. 32Figure 43 Recommended Admixture ............................................................................................. 33Figure 44 Slump Test Equipment .................................................................................................. 33Figure 45 Slump Test (10cm +/- 2cm) ........................................................................................... 33Figure 46 Formwork Installation..................................................................................................... 34Figure 47 Formwork Installation with ply-wood.............................................................................. 34

Figure 48 Anchor Bolts Protection during concrete pouring .......................................................... 34Figure 49 Curing methode ............................................................................................................. 35Figure 50 Curing methode ............................................................................................................. 35Figure 51 Curing methode ............................................................................................................. 35Figure 52 Concrete Repair cementous Mortar............................................................................... 37


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Figure 53 Concrete Cube Testing.................................................................................................. 38Figure 54 Concrete Cube Equipment ............................................................................................ 38

Figure 55 Concrete Cube Label..................................................................................................... 38Figure 56 Concrete Cube Label..................................................................................................... 38Figure 57 Concrete Cube Storage................................................................................................. 38Figure 58 Test result form.............................................................................................................. 39Figure 59 Honeycomb Concrete need to be rectified with non-shrink grout .................................. 41Figure 60 Compaction Equipment ................................................................................................. 42Figure 61 Compaction Equipment ................................................................................................. 42Figure 62 Compaction Equipment ................................................................................................. 42Figure 63 Layer-by-Layer Compaction .......................................................................................... 42Figure 64 Compaction Test Equipment ......................................................................................... 43Figure 65 Standard Operating Procedure For Compaction ........................................................... 43Figure 66 NSN Project Safety Instruction ...................................................................................... 43

Figure 67 NSN recommended Personal Protective Equipment..................................................... 43Figure 68 NSN recommended Personal Protective Equipment..................................................... 43Figure 69 Tool Box Meeting Template Figure 70 Job Safety Analysis Template ....................... 44Figure 71 NSN recommended Personal Protective Equipment Figure 72 Risk Activity ...... 44Figure 73 Site Safety Sign Figure 74 Site Safety Sign ..................................... 44Figure 75 Sample of Tower Material Packing List ......................................................................... 45Figure 76 Tower Material Factory inspection................................................................................. 45Figure 77 Tower Material Galvanizing ........................................................................................... 45Figure 78 Tower Material Packing ................................................................................................. 45Figure 79 Tower Material Transportation....................................................................................... 46Figure 80 Tower Material Transportation....................................................................................... 46Figure 81 Tower Material Transportation....................................................................................... 46

Figure 82 Tower Material Storage at Site ...................................................................................... 47Figure 83 Tower Material Segregation before Erection ................................................................. 47Figure 84 Tower Erection Equipment (manual winch)................................................................... 48Figure 85 Tower Erection Equipment (engine-driven winch) ......................................................... 48Figure 86 Tower Erection Equipment (gin pole) ............................................................................ 48Figure 87 Tower Erection Equipment (tools) ................................................................................. 49Figure 88 Tower Erection Equipment (tools) ................................................................................. 49Figure 89 Tower Erection Equipment (ongoing) ............................................................................ 49Figure 90 Tower Erection Equipment (ginpole, pulley, roles) ........................................................ 50Figure 91 Tower Erection Equipment (pulley, roles)...................................................................... 50Figure 92 Sample of NCR.............................................................................................................. 51Figure 93 Horizontal Feeder Tray with Support-Pole..................................................................... 52

Figure 94 Paint and Galvanize thick measurement (Elco-meter) .................................................. 53Figure 95 Tower Painting (Primer, if required)............................................................................... 53Figure 96 Tower Painting (Final Coat) ........................................................................................... 53Figure 97 Tower Identy Plate......................................................................................................... 54Figure 98 Shelter Foundation Construction ................................................................................... 55Figure 99 BTS Foundation, incl. Steel Base Frame....................................................................... 55Figure 100 Sun shelter................................................................................................................... 55Figure 101 BTS Foundation, incl. Steel Base Frame..................................................................... 56Figure 102 BTS Foundation, incl. Steel Base Frame..................................................................... 56Figure 103 PISM check list and fill in advisory............................................................................... 56Figure 104 Retaining Wall Construction ........................................................................................ 57

Figure 105 Retaining Wall Construction ........................................................................................ 57Figure 106 Access Road Construction .......................................................................................... 57Figure 107 Access Road Construction .......................................................................................... 57Figure 108 Genset Foundation Construction................................................................................. 59Figure 109 Genset installed at Site................................................................................................ 60


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Figure 110 Compound Fence ........................................................................................................ 61Figure 111 Compound Fence ........................................................................................................ 61

Figure 112 Compound Wall ........................................................................................................... 61Figure 113 Compound Gate .......................................................................................................... 61Figure 114 Compound Fence Foundation Construction................................................................ 62Figure 115 Compound Fence Foundation Construction................................................................ 62Figure 116 BRC-Compound Fence Construction .......................................................................... 62Figure 117 BRC-Compound Fence Construction .......................................................................... 62Figure 118 Compound Gate .......................................................................................................... 63Figure 119 Compound Gate .......................................................................................................... 63Figure 120 Compound Barbed Wire Construction......................................................................... 63Figure 121 Compound Brick Wall Construction............................................................................. 64Figure 122 Compound Brick Wall Plastering ................................................................................. 65Figure 123 Compound Brick Wall Painting .................................................................................... 66

Figure 124 Compound Overview ................................................................................................... 67Figure 125 Compound Light .......................................................................................................... 68Figure 126 Compound Light Sensor Box....................................................................................... 68Figure 127 Roof Top Antenna Mounting Structure Base (9 m Pole) ............................................. 70Figure 128 Roof Top Antenna Mounting Structure Base (12 m Pole) ........................................... 71Figure 129 Roof Top Antenna (15m Mini Tower)........................................................................... 71Figure 130 Roof Top Antenna Mounting Structure Base (15 m).................................................... 71Figure 131 Roof Top Antenna Mounting Structure Base (9 m Pole) ............................................. 72Figure 132 Roof Top Antenna Mounting Structure Base (3 m Pole) ............................................. 72Figure 133 Roof Top Antenna Mounting Structure Base (15 m Guyed Mast) ............................... 72Figure 134 Roof Top Antenna Mounting Structure Base (6 m Pole) ............................................. 72Figure 135 Roof Top Cable Tray Arrangement.............................................................................. 73

Figure 136 Access Lock Arrangement........................................................................................... 73Figure 137 Aviation Warning Light Installation............................................................................... 74Figure 138 Aviation Warning Light Control Box............................................................................. 74Figure 139 Aviation Warning Light Control Box Installation........................................................... 75Figure 140 Aviation Warning Light Control Box Installation........................................................... 75Figure 141 CKD Shelter Construction (outside)............................................................................. 76Figure 142 CKD Shelter Construction (outside)............................................................................. 76Figure 143 CKD Shelter Construction (inside cable tray arrangement)......................................... 76Figure 144 CKD Shelter Construction (wall installation)................................................................ 77Figure 145 CKD Shelter Construction (roof installation) ................................................................ 77Figure 146 CKD Shelter Construction (floor installation) ............................................................... 78Figure 147 CKD Shelter Construction (door installation)............................................................... 79

Figure 148 CKD Shelter Construction (accessories, grounding bus bar) ...................................... 79Figure 149 CKD Shelter Construction (air-conditioning installation).............................................. 80Figure 150 CKD Shelter Construction (alarm panel installation) ................................................... 80Figure 151 CKD Shelter Construction (alarm panel installation) ................................................... 80Figure 152 Equipment Room (outside view).................................................................................. 81Figure 153 Equipment Room......................................................................................................... 81Figure 154 Equipment Room (partitioning wall construction) ........................................................ 82Figure 155 Equipment Room (feed-through Roxtec) ..................................................................... 83Figure 156 Equipment Room (ACPDB) ......................................................................................... 85Figure 157 Shelter (ACPDB).......................................................................................................... 85Figure 158 Cable Tray Arrangement ............................................................................................. 85

Figure 159 Indoor Cable-tray......................................................................................................... 86Figure 160 Indoor Cable-tray Arrangement (Grounding)............................................................... 86Figure 161 Vertical Indoor Cable-tray Arrangement ...................................................................... 86Figure 162 Indoor Cable-tray Arrangement (wall anchoring)......................................................... 87Figure 163 Indoor Cable-tray Arrangement (ceiling anchoring)..................................................... 87


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Figure 164 Feed-Through (Roxtec) ............................................................................................... 87Figure 165 Indoor ACPDB ............................................................................................................. 88

Figure 166 Gland sealent............................................................................................................... 88Figure 167 Gland sealent............................................................................................................... 88Figure 168 Outdoor ACPDB .......................................................................................................... 89Figure 169 Outdoor ACPDB (Cable Feed-Through)...................................................................... 89Figure 170 Air-Conditioning ........................................................................................................... 90Figure 171 Air-Conditioning ........................................................................................................... 91Figure 172 Air-Conditioning (Control Box) - Thermostat................................................................ 92Figure 173 External Alarm Box...................................................................................................... 93Figure 174 Smoke Detector........................................................................................................... 93Figure 175 Heat detector ............................................................................................................... 93Figure 176 External Alarm (Intruder Alarm Sensor)....................................................................... 93Figure 177 Grounding Installation.................................................................................................. 96

Figure 178 Grounding Installation (Resistance Measurement)...................................................... 96Figure 179 Grounding Installation (Cad-Weld) .............................................................................. 96Figure 180 Grounding Installation (Maintenance Pit)..................................................................... 97Figure 181 Grounding Installation (Maintenance Pit inside) .......................................................... 97Figure 182 Lightning System (Air Terminal) .................................................................................. 98Figure 183 Lightning System (Cable Installation) .......................................................................... 98Figure 184 Tower Top Bus Bar Installation.................................................................................... 99Figure 185 Tower Bottom Bus Bar Installation .............................................................................. 99Figure 186 Layout of Aerial busbar.............................................................................................. 100Figure 187 Grounding System (Maintenance Pit closed) ............................................................ 102Figure 188 Grounding System (Maintenance Pit open)............................................................... 103Figure 189 Grounding labeling using critchley............................................................................. 106

Figure 190 Grounding labeling using critchley............................................................................. 106Figure 191 Grounding Principles and Test Equipment ................................................................ 107Figure 192 KWh Meter Panel closed (Greenfield Site) ................................................................ 109Figure 193 KWh Meter Panel open (Greenfield Site) .................................................................. 109Figure 194 KWh Meter Panel closed (Rooftop Site).................................................................... 110Figure 195 KWh Meter Panel open (Rooftop Site) ...................................................................... 110Figure 196 Gland sealent............................................................................................................. 110Figure 197 Gland sealent............................................................................................................. 110Figure 198 Self-Assessment Check-List...................................................................................... 111


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CW HB NI SE 2009 00CME HAND BOOK




ANNEX

ANNEX 1: NSN PROJECT SAFETY INSTRUCTION........................................................................ 113ANNEX 2: NSN HEALTH AND SAFETY POLICY............................................................................. 114ANNEX 3: TECHNICAL SITE SURVEY REPORT ............................................................................ 115ANNEX 4: SOIL TEST REPORT ....................................................................................................... 116ANNEX 5: STRUCTURAL DESIGN ANALYSIS................................................................................ 117ANNEX 6: CONCRETE ADMIXTURE MATERIAL ............................................................................ 118ANNEX 7: CONSTRUCTION SITES KICK OFF MEETING .............................................................. 119ANNEX 8: PILING RECORD ............................................................................................................. 120ANNEX 9: SITE MIX APPROVAL...................................................................................................... 121ANNEX 10: STRUCTURAL REPAIR MATERIAL.............................................................................. 122ANNEX 11: PROCEDURE OF SOIL BACKFILLING AND COMPACTION REQUIREMENT............ 123ANNEX 12: TOWER MATERIAL PACKING LIST ............................................................................. 124

ANNEX 13: TOOLS BOX SAFETY MEETING RECORD SHEET..................................................... 125ANNEX 14: PRE-INSTALLATION SITE MEETING........................................................................... 126ANNEX 15: GROUNDING PRINCIPLES & TEST EQUIPMENT....................................................... 127ANNEX 16: SELF ASSESSMENT CHECK LIST............................................................................... 128ANNEX 17: PILE INTEGRITY TEST ................................................................................................. 129ANNEX 18: NON-CONFORMITY REPORT ...................................................................................... 130ANNEX 19: JOB SAFETY ANALYSIS............................................................................................... 131ANNEX 20: CME TECHNICAL SPECIFICATION.............................................................................. 132ANNEX 21: CME GENERAL PROCESS........................................................................................... 133


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1. INTRODUCTION

Purpose of this document is to outline how the activities that are related with Civil, Mechanical andElectrical Engineering (CME) are to be performed by The Sub-contractor on behalf of NSN.

2. REMOTE BSC / RNC AND MAJOR SDH SITES

The Sub-contractor shall follow the requirements as stipulated in Part B (ii) Section 3 Appendix 1sections relating to

Electrical Systems Requirements

Air Conditioning System

Fire Alarm and Automatic Fire Extinguishing System

Access Control Systems

Environmental Monitoring System


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3. SITE ENGINEERING

3.1 Site Supervision

The Sub-contractor shall provide suitable supervision to ensure that the actual work on site is carriedout as specified in the detailed design and according to the Specification. This shall include a layer ofsupervisory staff that is independent of the teams that are carrying out the physical installation. Thisfurther includes all quality checks that are to be carried out.

3.2 Access and Use of Site

The Sub-contractor shall adhere to the access arrangements as agreed with the land lord in the BAK orSite Lease Agreements. Requests for any deviations from those arrangements that may be requiredduring the course of the works shall be made to the land lord. The Sub-contractor shall obtain all entry

permits, keys and ID materials etc as required for staff to enter the owners premises.3.3 Site Cleanliness

The Sub-contractor shall, as far as reasonably practical, maintain the site in a clean condition. Allrubbish and debris shall be collected as it accumulates and removed and disposed of by suitablemeans.

3.4 Site Facilities

The Sub-contractor shall be responsible for providing all water, electricity and other power sourcesneeded to complete the works and shall give notice and pay all fees to the respective organisations thatshall provide those services.

3.5 Setting Out and Drawings.

The Sub-contractor shall keep on site, and maintain up to date and in good condition, a full set ofapproved detail drawings. These shall be available for reference by the Contactors staff, any Subsub-contractors staff and for use by NSN.


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3.6 Security

The Sub-contractor shall be responsible formaintaining security on the site, sufficient tosafeguard all equipment and materials and toprevent any access to the site by persons otherthan those directly involved with the works.

Figure 1 Safety Sign

Figure 2 Safet Fence

Figure 3 Safety fence


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3.7 Technical Site Survey

A technical site survey has to be conducted to establish all relevantsite data as basis for the detailed site design.

TSSR form

Soil test form

Figure 4 Technical Site Survey Figure 5 Soil Test Record

Template Template

3.8 Detailed Site Design (Greenfield Site)

Following the TSSR, the Sub-contractor shall proceed with thecompletion and submission of the detailed site design.

3.9 Soil Investigation

For Greenfield Sites, the Sub-contractor shall arrange for a sub-soilinvestigation to be carried out. The resulting report shall providesufficient information for the contract or to produce a foundationdesigns for all structural elements which will form the site.

Three bore holes with a minimum depthe of 10m have to be drilled

to establish the relevant soil baring capacity of the site location. Thelocation of the holes has to be according to Figure 5. The soil testdata have to be recorded accordingly

The report will form part of the detailed site design.

3.10 Existing Tower Evaluation (Greenfield Site)

If the site is to utilize an existing tower structure, the Sub-contractorshall gather all information required to carry out an analysis of theexisting structure. The Sub-contractor shall complete the analysiswhich shall confirm that the existing structure is suitable or propose

what modifications would be required to make it suitable.

Figure 6 Soil Investigation on Site




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3.11 Static Calculations for Existing Building

For Rooftop Sites the Sub-contractor shall gather all informationnecessary to carry out calculations to determine if the building issuitable for the installation of all of the proposed site components.

The calculations, to form part of the detailed site design shall beendorsed by a licensed structural engineer.

The calculations have to been based on the original designdrawings or on rebar-scan results in conjunction with reboundhammer test results.

SDA template

Figure 9 SDA Template

Figure 10 Re-bound Hammer Test




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3.12 Detailed Design Package

The Sub-contractor shall submit the complete site detailed designpackage, including the following information:

TSS Report Preliminary Lease Sketch / Site Map Site Layout Drawings / Site Equipment Layout Drawings Site Grounding and Lightning Protection System Drawings. Site Electrical Diagrams / Layout of PLN connection.

Detailed Drawings of Antenna Support Structures. Detail of Aircraft Warning Light System Soil investigation Report or Tower Evaluation or Static

Calculations Foundations Design Calculations (Greenfield Sites) Foundations Detail Design Drawings (Greenfield Sites),

including reinforcement bending schedule.

Details and Design Calculations for other structuralelements such as retaining walls, access roads & bridgesetc

Details of all Rooftop Load Connections (Rooftop Sites) Layout and details of any temporary works required. Foundations or Load Connections are applicable to all

components on the site.The design shall be applicable to the installation of the type of site

required and likely future expansion as indicated by the SAM. Thedrawings shall have sufficient references and dimensions toexisting permanent features that shall allow the accurate setting outof the exact required position and level for every component of thesite.

The complete detailed design package including all calculationsshall be attached with the Site Specific Documentation. Importantdetails shall be enlarged. As a guide the following scale format hasto be used.

Site Map scale not required

Site access layout up to 1:500

PLN connection route up to 1:500

Site Layouts 1:200, 1:150, 1:100, 1:50

Equipment Rooms and Shelter Layouts 1:30

Tower Outlines 1:200

Details of site components 1:50, 1:30, 1:25, 1:20, 1:10, 1:5

Where more than one scale is used on a drawing, the scale shall beclearly indicated under each element.

Sub-contractor shall replace or rectify all the work which is not inaccordance with agreed design specification on their own cost


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3.13 Tower Foundations

3.13.1 Standard Tower Foundation Designs

The Sub-contractor shall provide a range of standard foundation designs and recommendations foreach type of tower offered. Prior to deployment the designs shall be submitted to NSN for approval.

The standard design shall be to suit conditions where the bearing capacity is greater than 1kg/cm2.

The design of reinforced concrete foundations shall conform to local standards and the followingrequirements.

FOS against uplift force to EIA-222-F

FOS against compression force 2

Reinforced concrete design in accordance with ACI 318RM (1999) or BS8110

The concrete pedestal shall protrude at least 0.5m above finished ground level.

Cover to reinforcement below ground shall be at least 75mm.

The minimum compressive strength at 28 days shall not be less than 225kg/sq cm for all structuralelements

Steel Reinforcement shall be in accordance with JIS G 3112 or ASTM A305 and shall be deformed bar.

The foundation designs shall be the most economical with respect to concrete volume, excavationdepth, dimensions and reinforcement quantities.

All designs shall be endorsed by a qualified structural engineer, with a SKBI license.

3.13.2 Site Specific Foundation Design

Following completion of the soil investigation, The Sub-contractor may propose and justify the use ofone of the standard designs, or shall, if none are suitable, propose a special design for the site. Thejustification shall be endorsed by a licensed structural engineer.

The special design shall use the same criteria as in clause 4.1 (follow the link)

All designs shall be endorsed by the licensed structural engineer

The adopted design shall be submitted with the detailed design package.

3.14 As Built Drawings

The Sub-contractor shall submit, as a part of the Site Specific Documentation, the As Built drawings tothe requirements of the relevant section of 3.12 (follow the link)


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4. CONSTRUCTION

4.1 Quality Gates for Construction Works (CW)

4.2 Kick Off Meeting

The kick-off meeting has to be attended by:

NSN Sitac-Coordinator

NSN CME-Inspector

NSN CME-Manager (optional)

Sitac-Subsub-contractor Representative

CME-Subsub-contractor Representative

A sample of the kick-off meeting protocol is given in Figure 9.

NSN-inspector control point G1

KOM template

Figure 13 Kick-off MeetingTemplate

Figure 14 Site Location clearlystacked out

PartnerAcceptance Test Proc.

G6

NSN

Acceptance Test Proc.

G7

Acceptance TestResult

AcceptanceAchievement

Inde endent Q-Team Pro ect

Kick-off meeting(at site)

Excavation&

Pile Construction

Rebar Constr.& Anchor

Bolt Setting

ConcretePouring

Tower Erect.&

ME works

Fence&

Yard

InternalAcceptance

Acceptance

G1 G3G2 G4 G5 G6 G7

Quality & Safety Gates

CW Functional Manager / Site Inspector

Quality audit team

Rebar Constr.-& Anchor Bolt Form

G3

PISM G5

Slump Test- &

Concrete SampleForm

G4

Excavation- &Pile Form

G2

Documentation Control

- KOM-Protocol- Approved Detailed Design Drawings- JSA (Job Safety Analysis)- Site Log Book- CPR Form- Hidden Works Doc. Templ.- Project Implementatation Plan- Rebar SOP- Concrete Pouring SOP

- Compaction SOP

G1


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4.3 Site Clearing and Demolition

The Sub-contractor shall remove and dispose of trees, brush, othervegetation, rubbish and other obstructions on site as necessary forthe construction of the approved site design. Any pits or trenchesresulting from this activity will be backfilled with suitable material.

The clearing includes the removal of all stumps and roots.

The resulting waste material will be disposed of by the Sub-contractor.

All necessary precautions will be taken by The Sub-contractor toprevent any damage to structures, trees existing services or other

features that will remain.Figure 15 Site Location clearly

stacked out

Figure 16 Site Location cleared from Vegetation and Debris

Figure 17 Site location clearedready for Excavation


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4.4 Bored Piling

4.4.1 General

If the foundation design requires that bored piles be deployed thenThe Sub-contractor shall employ a specialist organisation to carryout their installation.

Unless otherwise specified, concrete, testing of concrete,reinforcement and formwork shall comply with the requirements ofother parts of this specification.

Piling shall conform to the principles of BS 8004

4.4.2 Setting Out

The Sub-contractors internal process shall ensure that the settingout is carried out by a competent surveyor. The Sub-contractorshall be responsible for the accuracy of the location of each pile.Any errors in the setting out shall be made good at the expense ofThe Sub-contractor.

Reference pegs shall be installed at each pile location so thatlocation of each pile can be checked or re-established after boringhas commenced.

The pile head following installation shall be within 100mm in either

direction from the design position.

4.4.3 Equipment and Personnel

The work shall be carried out by full time operators and supervisorystaff who are experienced in the installation of the proposed piletype.

The equipment shall be capable of safe and efficient installation.Sufficient units of equipment shall be provided to achieve theagreed construction schedule.

4.4.4 Rejected Piles

Any piling work rejected by NSN due to not being in accordancewith this specification shall be replaced or rectified by the Sub-contractor. This may include the reinstallation of piles, theinstallation of additional piles and the design and construction ofmodified foundations.

Figure 18 Bore Pile equipment



Figure 21 Bore pile equipment


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4.4.5 Records

The Sub-contractor shall keep a record of the installation work thatshall form part of the final documentation that shall conform to otherparts of section 4.4.12 (follow the link). The form of the recordsshall be agreed before installation commences. All unexpectedboring or installation conditions shall be noted in the records.

4.4.6 Concrete

Concrete shall conform to other parts of section 4.4.16 (follow thelink) of this specification.

Slump shall be between 25 and 100mm where placed directly in a

water free shaft. If placed by tremie, the slump may be up to175mm.

4.4.7 Excavation

Piles shall not be bored next to other piles that have been cast lessthan 24 hours earlier.

If necessary, The Sub-contractor shall use means such as steelcasings and / or drilling fluid to maintain the stability of the sides ofthe boreholes. Casings shall project at least 1m above and belowthe unstable stratum. The internal diameter of the casing shall be atleast as large as the required pile diameter and shall be of uniformcross section.

Where practical, boreholes shall be inspected before concreting. Allloose material shall be removed from the walls and the bottom priorto concreting.

Excavated material shall not be used elsewhere on the sites unlessit is shown to be suitable material for compacting.

Figure 22 Land preparation forBore Piling


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4.4.8 Placement of Reinforcement

Reinforcement shall conform to section 4.4.14 (follow the link) ofthis specification.

Cages shall be sufficiently rigid to ensure that they remain at theircorrect level during the placing of concrete and extraction oftemporary casings. Reinforcement shall be maintained in its correctposition throughout concreting with a minimum cover of 75mm.Spacers of suitable material shall be provided at every 3m or less.

The main longitudinal bars in piles not exceeding 12m in lengthshall be one continuous length. In piles longer than 12m, joints shallbe staggered. Lap lengths of joints shall be specified by the design

engineer and shall comply with BS8110.

The reinforcement shall project far enough above the pile cut offlevel to ensure correct bond lengths in the cap. The designengineer shall state these bond lengths in the design and they shallbe shown on the detailed drawings.

Figure 23 Bore pile rebar cage


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4.4.9 Concreting of bore Piles

The method adopted shall produce a dense homogenous mass ofconcrete. In wet holes, concrete shall be placed under drilling fluidby use of a tremie pipe in accordance with BS8004. At all times,sufficient quantities of concrete shall be kept in the pipe and hopperto ensure that the pressure from the concrete exceeds that from thewater / drilling fluid. The Sub-contractor shall ensure that there is acontinuous supply of concrete to achieve this.

In dry holes, concrete shall still be poured through a tremie to avoidexcessive free fall of the concrete.

The outlet of the tremie shall be kept at least 1.5m below the

surface of the concrete throughout the pour.

Cold joints in a pile will not be permitted.

Temporary casings shall be removed within 2 hours of completionof the pour and while the concrete remains workable enough sothat the concrete is not lifted with the casing. If casings areremoved whilst concreting proceeds, a sufficient head of concreteshall be maintained to prevent entry of groundwater.

The top of the pile shall be brought up above the required cut offlevel by an amount sufficient to ensure sound concrete at the cut off

level.On completion of the pour, the actual quantity of concrete usedshall be recorded and compared to the calculated volume required.Significant differences shall be reported to the design engineer whoshall propose and carry out appropriate tests to ensure theadequacy of the pile. The measurements and calculations shallform part of the final documentation that The Sub-contractor willsubmit to NSN.

Figure 24 Tremie equipment


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4.4.10 Cutting Back of Bore Piles

After completion of the piling, the pile cap shall be excavated andthe piles shall be cut back to the correct cut off level. Thereinforcement shall be trimmed and if necessary bent as indicatedin the designs to provide sufficient bond to the cap.

The Sub-contractor shall check the positions of the pile heads toensure that they are within the tolerance. The checks shall berecorded and shall form part of the final documentation that theSub-contractor will submit to NSN.

NSN-inspector control point G1a(only if bore-pile foundation is required)

Figure 25 Cutting back of borepiles

Figure 26 Cutting back of bore

piles


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4.4.11 Integrity Testing

Where records or observations indicate possible deficiencies withan installed pile, NSN may request that The Sub-contractorarranges integrity testing. The tests shall be carried out by anindependent testing organisation at The Sub-contractors expense.

If the results of the tests show that any pile is defective, the pileshall be rejected unless The Sub-contractor can demonstrate to theapproval of NSN that effective remedial measures can be carriedout.

Sonic_Integrity_Test.pdf

Figure 27 Integrity testing principles

NSN-inspector control point G1b(only if bore-pile foundation is required)

Figure 28 Integrity testing

Figure 29 Integrity testing


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4.4.12 Piling Records

The Sub-contractor shall record the following during the installationprocess.

Supervisors Name.

Description and Photos of Equipment Used.

Design Length, Diameter and Reference No of Pile.

Existing Ground Level.

Cut Off Level, Pile Bottom Level.

Actual Length.

Log of material encountered in bore and levels of stratachange.

Speed of boring through each different strata.

Details of obstructions and other unusual conditions.

Details of casings used levels, lengths, permanent,temporary

Types of drilling / stabilising fluids used.

Records of any collapses or loss of drilling / stabilising fluid.

Depth of bore.

Details of any inclination or displacement of bore.

Length of reinforcement cage installed.

Water table level

Concrete cube test results.

Slump test results.

Date of concrete pour.

Mix design.

Records of concrete volume used and comparison tocalculated volume.

Daily weather conditions throughout installation.

Description of method of concreting.

Photographs of all stages of installation.

Piling recordtemplate.doc

Figure 30 Piling record template


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Records of concrete volume used and comparison tocalculated volume.

Daily weather conditions throughout installation.

Description of method of concreting.

Photographs of all stages of installation.

The records shall be presented to NSN in an agreed format with aninterpretation and assessment of the quality / integrity of theinstalled piles.


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4.4.13 Excavations

Prior to the commencement of excavations, The Sub-contractorshall make every effort to ascertain if any existing buried serviceswill be affected. The Sub-contractor shall plan how to deal withthem to prevent any damage being caused to them and limit theeffect to the construction program.

Prior to commencement of excavations, The Sub-contractor shalltake all necessary precautions and make all necessary plans toensure that existing buildings near to the site are not damaged orweakened by the excavation.

The minimum size necessary to install the foundation shall be

excavated. If any excavation is made too deep, the proper levelshall be re-established by using concrete as a backfill.

The Sub-contractor shall inspect the base of all excavations andsatisfy himself that the conditions are as expected in the soilinvestigation and consistent with the assumptions made in thedesign. No footing shall rest on fill.

The Sub-contractor shall ensure that the bases of excavations areprotected from deterioration and that the bases are exposed for aminimal period of time. The Sub-contractor shall provide allnecessary pumping to drain and keep excavations free from water.

The bases shall be protected with lean concrete blinding at least75mm thick.

The Sub-contractor shall ensure that the excavations are correctlysupported to avoid any collapse and that the materials to do so areavailable on site before commencement of the excavation.

NSN-inspector control point G2

Figure 31 Excavated foundation /safe storage of excavated material

Best Practice Excavation: Allexcavations 8 feet or less indepth which have unsupportedvertically sided lower portionsshall have a maximum verticalside of 3 feet.

UNSUPPORTED VERTICALLY SIDEDLOWER PORTION (MAXIMUM 8 FEET INDEPTH)

Best Practice Material Storage:The excavated soil has to stored1.0m from the top corner of theexcavated area.


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4.4.13.1 Sheet Piling

The Sub-contractor may propose other means of supporting thesides of the excavation.

Material: The sheet piling shall be made of steel and may be new orused material. The sheeting shall have a minimum yield strength of38.5 ksi (265 MPa) unless otherwise specified.

The sheeting, used by the Sub-contractor, shall be identifiable andin good condition free of bends and other structural defects. NSNsapproval will be required prior to driving any sheeting. All drivensheeting not approved by NSN shall be removed at the Sub-contractors expense. Construction. The Sub-contractor shall verify

locations of all underground utilities before driving any sheet piling.Any disturbance or damage to existing structures, utilities or otherproperty, caused by the Sub-contractors operation, shall berepaired by the Sub-contractor in a manner satisfactory to NSN.

The Sub-contractor shall be responsible for determining theappropriate equipment necessary to drive the sheeting to the tipelevation(s) specified on the plans or according to the Sub-contractors approved design. The sheet piling shall be driven, as aminimum, to the tip elevation(s) specified, prior to commencing anyrelated excavation. If unable to reach the minimum tip elevation, theadequacy of the sheet piling design will require re-evaluation by

NSN prior to allowing excavation adjacent to the sheet piling inquestion. The Sub-contractor shall not excavate below themaximum excavation line shown on the plans without the priorpermission of NSN. The sheet piling shall remain in place until therepresentative of NSN determines it is no longer required.

Figure 32 Sheet Piling

Figure 33 Sheet Piling


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4.4.13.2 Dewatering (Wellpoint Dewatering)

Sub-ground Dewatering or Wellpointing as it is often called is amethod of controlling or lowering the level of sub-ground waterwithin an aquifer.

In modern practice Wellpointing is considered most suitable forrelatively shallow excavations up to 6.5 metres deep in stratifiedsoils, especially where the water table must be lowered very nearto an underlying bed of clay or impermeable rock.

Wellpoint systems typically consist of the following:Small diameter pipe known as (riser pipe) fitted with a fine filter(wellpoint filter) this filter prevents fines entering into the system

and being removed from the ground in the pumped water.

This riser pipe is connected above ground to a flexible pipe via acontrol valve to the header pipe which in turn connects to thesuction connection of a specialist vacuum wellpoint pump.

The discharge side of the wellpoint pump is connected via thedischarge pipe to a settlement tank which further collects any finesand then on through the discharge pipe to the discharge point.

Once the pump is switched on it creates vacuum and pulls waterout of the ground thus lowering the sub ground water level and

pumps the water to the designated discharge point.

The Wellpoints are jetted into the ground using a high pressurewater pump (jetting pump) delivering water down a steel tube(jetting tube) to a maximum working depth of 6.5 metres.

The Wellpoint filter and riser pipe are installed along with agranular filter pack to aid drainage and then connected to the thesystem.

Wellpoint systems are very effective in a wide range of soils fromfine silty sand to corse gravels, single stage Wellpoint systems areused to a maximum depth of 6.5 metres, for deeper excavationstwin stage Wellpoint systems can be deployed.

The equipment used falls into two categories the above groundequipment which can be re used and is usually hired or rented andthe equipment below ground (risers and filters) which are normallyregarded as disposable items and as such are sold to NSN.

The pumps that are required for Wellpointing duties are critical tothe efficiency of the system and must have excellent air handlingand air separation capabilities as such they are regarded as

specialised units.

Figure 34 Wellpoint Dewatering

.

Figure 35 Surface DewateringPump

Figure 36 Submersible DewateringPump


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4.4.14 Reinforcement

Bars shall be of deformed type in accordance with JIS G 3112 orASTM A305

The bars shall be clean and free from grease, oil, loose rust orscale or other materials that may reduce the bond. The bars shallbe stored on site in a suitable manner to achieve preventcontamination by such materials.

Bars used shall be of the steel grade stipulated in the detaileddesign drawings. Bars bent on site shall be bent to the shapesshown in the design. Proper equipment shall be used to ensure thatthe correct and smooth radii are achieved. All bars shall be bent

cold. Re-bending of reinforcement previously bent shall not bepermitted.

The reinforcement shall be placed and secured to form a rigid mator cage as indicated in the site design. Securing shall be doneusing binding wire of at least 18 gauge. All intersections shall betied except where the spacing is less than 300mm in each directionwhen alternate intersections may be tied. In any case, allintersections around the perimeter of a pad or slab shall be tied.

Lapped splices shall only be used if shown on the detailed design.The laps shall be of the lengths shown in the design.

Chairs and spacers used to support the reinforcement against thebottom or formwork shall be used to ensure the correct cover isachieved.

Substitutions of different bar sizes shall only be permitted followingwritten approval by the design engineer. Details of substitutions andthe authorisat

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