tender document (sample).pdf

SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS)

TENDER DOCUMENT

FOR

THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE

UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS

2010

CONSULTANT: BLANC Consultant Firm No. 178, Second Floor, Green Heights Commercial Centre, Jalan Lapangan Terbang, 93250 Kuching, Sarawak, Malaysia. Tel: 082-416858 Fax: 082-416888

ADEBNATH

Rectangle

CONTENTS Pages

1. FORM OF AGREEMENT FA-1 to FA-2 2. FORM OF TENDER FT-1

3. APPENDIX TO FORM OF TENDER APP-1

4. NOTICE TO TENDERERS NT-1

5. INSTRUCTION TO TENDERERS IT-1 to IT-4

6. LETTER OF ACCEPTANCE OF TENDER LA-1 to LA-2

7. BANK GUARANTEE FOR PERFORMANCE BOND (WORKS) BG-1 to BG-3

8. PREAMBLE TO SUMMARY OF TENDER PRE-1 to PRE-4

9. SUMMARY OF TENDER ST-1 to ST-2

10. SCHEDULE OF RATES SR-1 to SR-26

11. GENERAL CONDITIONS OF CONTRACT C-1 to C-2

12. ADDENDUM TO GENERAL CONDITIONS OF CONTRACT ADD/C-1

13. SPECIFICATIONS SP 1.1 to SP 9.2

APPENDICES APPENDIX A - LIST OF DRAWINGS APPENDIX B - BOREHOLE LOGS

FORM OF AGREEMENT

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THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS

FORM OF AGREEMENT

THIS AGREEMENT made the …………………… day of ……………………… 20 ……………

BETWEEN Swinburne University of Technology Sarawak (SUTS) (hereinafter called “the Employer”) of one part and …………………………………………of (or whose registered office is situated at ………………………………………………………………………………………………………)

(hereinafter called “the Contractor”) of the other part. WHEREAS the Employer is desirous that certain works should be executed, viz : THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS …………………………………………………………………………………………………………... and has accepted a Tender by the Contractor for the execution of the works. NOW IT IS HEREBY AGREED AS FOLLOWS :- 1. In this Agreement words and expressions shall have the same meanings as are

respectively assigned to them in the General Conditions of Contract and the Addendum to General Conditions Of Contract hereinafter referred to.

2. The following documents shall be deemed to form and be read and construed as part

of this Agreement, viz :- (a) The said Tender; (b) The Summary of Tender, Schedule of Rates and Addendum to Form of

Tender; (c) The Specifications and Appendices; (d) The Contract Drawings; (e) The General Conditions of Contract (PWD 75 Rev. 5/61) and the Addendum

to General Conditions of Contract; (f) Instruction to Tenderers; and (g) The Letter of Acceptance. 3. For the consideration hereinafter mentioned, the Contractor will in accordance with

the provisions of this Agreement, execute and complete the Works shown upon the said Drawings and/or described by or referred to in the said Specifications, Summary of Tender and General Conditions of Contract.

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4. The Employer will pay to the Contractor the sum of Ringgit Malaysia………………….. or such other sum as shall become payable hereunder at the times and in the manner provided by this Agreement.

IN WITNESS whereof the parties hereunto have hereunder set their respective hands and official stamps the day and year first above written. The official stamp of Sarawak Construction ) (1963) Sdn Bhd (“the Employer”) is ) hereunto affixed ) ………………………………………………

) GENERAL MANAGER/ AUTHORISED ) OFFICER

) in the presence of :- ) ) Name …………………………………… ) ) Occupation ……………………………. ) ) Address ………………………………… ) ……………………………………………… ) Witness …………………………………………… ) Signed by ………………………………. ) (Name of Contractor) ) ) (I.C. No. ………………………………… ) ……………………………………………… for and on behalf of the Contractor ) Contractor’s Signature ) ) ) In the presence of :- ) ……………………………………………… ) Contractor’s Official Stamp Name …………………………………… ) ) Occupation ……………………………. ) ) Address ………………………………… ) ……………………………………………… ) Witness …………………………………………… )

FORM OF TENDER

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FORM OF TENDER

To : Swinburne University of Technology Sarawak (SUTS), Jalan Simpang Tiga,

93350 Kuching, Sarawak, Malaysia.

THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS Gentlemen, Having examined the Drawings, Summary of Tender, Schedule of Rates, General Conditions of Contract with the Addendum to General Conditions of Contract and Specifications for the above-named Works, we offer to execute, complete and maintain the whole of the said Works in conformity therewith and in accordance with the said Drawings, Summary of Tender, Schedule of Rates, General Conditions of Contract and Specifications for the sum of Ringgit Malaysia ………………………………………………………… …………………………… (RM …………………) (which includes the Provisional or Prime Cost Sums referred to in the above documents) or such other sum as may be ascertained in accordance with the said Conditions. We undertake to complete and deliver the whole of the Works comprise in the Contract within twelve (12) months from the date of possession of site or within such extended time as provided for by the General Conditions of Contract. If our tender is accepted we will, when required, provide surety in the amount stated in the Appendix to Form of Tender for the due performance of the Contract in accordance with Clause 5 of the General Conditions of Contract. We agree to abide by this Tender for the period of one hundred and twenty (120) days from the date fixed for receiving the same and it shall remain binding upon us and, may be accepted at any time before the expiration of that period. Unless and until a formal Agreement is prepared and executed, this Tender, together with your written acceptance thereof, shall constitute a binding Contract between us. We understand that you are not bound to accept the lowest or any tender you may receive. We are, Gentlemen, Yours faithfully, Signature and Stamp of Contractor ………………………………………… Name : ………………………………………… Address : ………………………………………… ………………………………………… Tel. No. : ………………………………………… Designation : ………………………………………… Date : …………………………………………

APPENDIX TO FORM TENDER

APP-1

APPENDIX

DETAILS TO APPLY TO APPENDIX TO GENERAL CONDITIONS OF CONTRACT

Clause

Amount of Surety 5 An amount equal to …………(%)

of the Contract sum. Defects Liability Period 19 & 35(f) ……………………………………. Time for Completion 26 ……………………………………. Liquidate and Ascertained 28 A sum of ………………… PLUS Damages ………….. ……….………………. Bonus for Completion ahead of 26(d) * RM…………….…………………. Time for Completion ……………………………………. Period of Interim Certificates 35(a) ……………………………………. Minimum Amount of Interim 35(a) ……………………………………. Certificates Limit of Retention Fund 35(c) ……………………………………. * See Addendum to General Conditions of Contract

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Twenty Four (24) months

Twelve (24) months

RM500.00 per Day or Part Thereof

Monthly

RM150,000.00

Five Percent (5%) of Contract Sum

10,000.00 per Month or Part Thereof

RM100,000.00

NOTICE TO TENDERERS

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NOTICE TO TENDERERS

(a) Tenders are invited for the “The Construction and Completion of the Proposed

Expansion Plan of Swinburne University of Technology (SUTS) at Jalan Uplands” addressed to “Swinburne University of Technology Sarawak (SUTS)” not later than ……………….. on the ………………

(b) The Tender Documents can be collected from the office of BLANC Consultant Firm

from the ……………………… The tenderer will be required to pay a non-refundable tender document fee of RM400.00 payable to BLANC Consultant Firm.

(c) A Contractor may not submit more than one tender in respect of the contract. (d) Mutilated or defaced tender forms may be rejected. (e) The work or service, for which this tender will be received, shall be carried out in

accordance with the Tender Specifications and Form of Tender together with the Terms and Conditions and Specifications attaching thereto and such detailed instructions as may be necessary during the performance of this work or service.

(f) The Contractor shall state in his tender ONE SUM for the thorough completion of the

work as shown and described in the Tender Specifications and Form of Tender, inclusive of all contingencies and liabilities to which he is or may become liable under the said Terms and Conditions and Tender Specifications.

(g) The Contractor shall provide certified photocopy of (a) Extract of Business Names

Ordinance in the case of sole proprietor/firm and (b) Form 24 and 49 in the case of limited company, must be submit together with the Form of Tender giving details to include names of shareholders.

(h) The Contractor whose tender is accepted shall be required to enter into a formal

contract with Swinburne University of Technology Sarawak (SUTS) for the due execution of the work.

(i) The tender will remain open for acceptance for a period of one hundred and twenty

(120) days from the date the tenders close. (j) Before work commences on the Contract, the Contractor shall be required to provide

Performance Bond in the form of cash or an approved security deposit in the form of cash or an approved Banker’s Guarantee equal to 5% of the tendered sum. This deposit will be released upon satisfactory completion of the contract.

(k) Unless and until a formal Agreement is prepared and executed, the tender

documents namely Form of Tender, General Conditions of Contract, Specifications and this Notice, together with the letter of acceptance from Swinburne University of Technology Sarawak (SUTS) issued within the validity period shall constitute a binding Contract between Swinburne University of Technology Sarawak (SUTS) and the Contractor.

(l) Swinburne University of Technology Sarawak (SUTS) does not bind itself to accept

the lowest or any tender.

NSTRUCTION TO TENDERERS

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SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS

INSTRUCTION TO TENDERERS

1. GENERAL These Instructions to Tenderers, in so far as they may affect the execution of the

contract, shall be deemed to form part of the Contract. The whole of the Works set forth in the Drawings, Summary of Tender, Schedule of

Rates and Specifications will be part of the Contract, subject to the General Conditions of Contract.

The relevant clauses stated in this Instruction to Tenderers should be read closely

with the General Conditions of Contract. 2. TENDER DOCUMENT

The Tender Documents shall consist of the following:- (i) General Conditions of Contract with the Addendum (ii) Instruction to Tenderers (iii) Form of Tender and Appendix to Form of Tender (iv) Summary of Tender and Schedule of Rates (v) Specifications (vi) Drawings. 3. TENDERER TO OBTAIN ALL INFORMATION/SITE EXAMINATION The Contractor shall be deemed to have read the tender documents and have visited

the site before tendering and acquainted himself to the nature, extent and practicability of the works. He shall be deemed to have included in his tender for any costs in respect of availability or lack of access, working space, the nature of the ground conditions and any other limitations imposed by the site and its surroundings.

4. INTERPRETATION OF TENDER DOCUMENTS If any Tenderer is in doubt as to the true meaning of any part of the Tender

Documents, he should at once notify the Engineer not less than ten (10) days prior to the submission of tenders and request clarification before submitting his Tender, interpretations of the Tender Documents will be valid only if made by formal Addenda by the Engineer as described in Clause 7 hereof.

5. ADDENDA Addenda may be issued prior to the date for submission of Tenders to clarify or

modify the Tender Documents in part or in total. Every Addendum issued will be distributed to each Tenderer and shall become part of the Tender Documents. Receipt of each Addendum must be acknowledged on the form issued with the Addendum and must be submitted together with the Form of Tender. Failure to acknowledge any Addendum may render the Tender being rejected.

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6. ORAL INTERPRETATION Oral interpretation of any of the Tender Documents requested and received by any

tenderer shall not be considered to modify any of the provisions of the Tender Documents. Any clarification or modification to any of the Tender Documents shall be made in writing in the form of Addenda.

7. STANDARD OF WORKMANSHIP AND MATERIALS All workmanship, materials and components throughout shall comply with either:- (a) The relevant Malaysian or British Standard or Code of Practice current on the

date of closing Tenders, or (b) Other Standard or Codes of Practice proposed by the Tenderer providing that

these Standards or Codes of Practice are equivalent or superior to the relevant British Standard or Code and that two ( 2) copies in English of each standard and Code of Practice shall be provided by the Tenderer with the Tender.

8. EXECUTION OF TENDERS The Tender must be signed or sealed or otherwise executed in such manner that it

shall be binding on the Tenderers if accepted. The Tender Documents shall be signed by the Contractor or duly authorized

representative of the Company. Power of Attorney or certified copies thereof granting authority to sign shall be

enclosed. 9. THE TENDER The Tenderer is required to complete all of the Tender Documents including :- (a) The Form of Tender and Addendum to Form of Tender (b) The Summary of Tender and Schedule of Rates (c) All Appendices (d) ‘Power of Attorney’, Affidavits together with Agreement of Association and

any other documents necessary to authenticate his Tenderer. Where documents to be signed by the Tenderer extend for more than one page,

each page of the individual forms shall be initialed by the Tenderer. 10. FILLING OF APPENDICES Where required, the tenderer is required to complete fully all Appendices with

accurate details. 11. CONFIDENTIALITY OF DOCUMENTS The Tender Documents shall be treated as private and confidential.

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12. COST OF TENDERING Tenderers will not be reimbursed for any expense incurred in the preparation or

submission of Tender. 13. COST OF TRANSMITTING DOCUMENTS All charges whatsoever relating to the collection, delivery and return of the Tender

Documents and additional copies thereof shall be the liability of the Tenderers. 14. IMPORTED CONSTRUCTIONAL PLANT AND MATERIALS The Tenderer shall satisfy himself that important licenses for each and any

Constructional Plant and Materials he proposes to import into Malaysia for the execution of the Works will be issued by the relevant authority. The Employer shall not be held liable for any rejection or delay in issuing of such license.

The attention of the Tenderers is drawn to the fact that importation of materials,

supplies and equipment is subject to the approval by the Ministry of Trade and Commerce. The Tenderers shall ascertain for themselves through enquires with the Ministry of Trade and Commerce on the rules, regulations and custom duties for the import of materials and equipment to be incorporated in the works and make appropriate allowances in their tender prices.

15. PERFORMANCE BOND Before work commences on the Contract, the successful tenderer shall be required

to provide Performance Bond in the form of cash or an approved security deposit in the form of cash or an approved Banker’s Guarantee equal to 5% of the tendered sum. This deposit will be released upon satisfactory completion of the contract.

16. OUTLINE CONSTRUCTION PROGRAMME On commencement of the work, the successful tenderer shall submit : (a) A programme showing the order in which the Tenderer proposed to carry out

and complete the Works within the Contract Period; (b) An outline of the method by which the Tenderer proposes to complete the

Works within the Contract Period; and (c) Equipment and plant proposed together with the numbers of workers (both

skilled and unskilled) to be employed during the various stages of the Contract Period.

17. JURISDICTION ACCORDING TO MALAYSIAN LAW It shall be understood that any tenderer who participates in any manner in the

Tender consents to submit jurisdiction in Malaysia on any question or matter arising from the Tender Documents, award and implementation of the Contract, and binds himself to accept the judgement or order of any such court of tribunal of competent jurisdiction.

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18. LANGUAGE OF THE BID The Tender prepared by the Tenderer and all correspondence and documents

relating to the Tender exchanged by the Tenderer and Sarawak Construction (1963) Sdn Bhd shall be written in English.

19. CUSTOMS DUTY AND SALES TAX The Contractor shall pay all customs and Excise Duties, Import Surtax, Port Dues,

Landing Charges and Sale tax upon materials and equipment, either imported into or purchased within Malaysia for incorporation into the Works. The Contractor should allow all rates quoted in these Tender Documents to include in for Customs and Excise Duties, Import Surtax, Port Dues, Landing Charges and Sales Tax. The Contractor shall not be reimbursed for all these items.

20. C.I.D.B. CONTRIBUTION The Employer shall make contribution of levy to the Construction Industry

Development Board (CIDB). Thus, the Contractor is not required to price the levy contribution in his tender and also not required to effect payment to CIDB in respect of levy contribution for his works.

LETTER OF ACCEPTANCE OF TENDER

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LETTER OF ACCEPTANCE OF TENDER

To : …………………………………………………… …………………………………………………… …………………………………………………… …………………………………………………… (Contractor) Contract No.: TENDER FOR THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS 1. You are hereby informed that your Tender for the above mentioned Works is

accepted, subject to the Conditions of Contract, Specifications, Schedule or Rates and Summary of Tender, Addendum, Form of Tender and this letter, in the sum of Ringgit Malaysia ………………………

2. Your Tender, as defined above, together with this Letter of Acceptance thereof, shall

constitute a binding contract between yourselves and Swinburne University of Technology Sarawak (SUTS). You will be required however, to execute in due course, an Agreement in the form annexed to the tender documents.

3. You will be notified by the Swinburne University of Technology Sarawak (SUTS)

when the Contract documents are ready for your signature. 4. Attention is drawn to the General Conditions of Contract, whereby as precedent to

commencement of Work and not later than the day you execute the formal Contract Agreement, you will be required to deposit with the Employer a performance Bond in the form of a Bank Guarantee by an acceptable financial institution in the sum of Ringgit Malaysia ………………… ……………… being five percent (5%) of the Tender Sum, for the due performance of this Contract.

5. You will also be required, at the same time, to deposit with the Engineer, the

Workmen’s Compensation and Insurance Policies and to produce for inspection the receipts for premiums paid.

6. This Letter of Acceptance does not constitute an order for you to commence work.

The order to commence work will be issued to you separately. The order to commence work will also contain the date of possession of site.

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7. This letter is sent to you in duplicate. Please return the original duly signed and witnessed where indicated, to this office and retain the copy.

…………………………………………… Swinburne University of Technology Sarawak (SUTS) _________________________________________________________________________ The undersigned hereby acknowledges receipt of the above letters, copy of which has been retained, and confirm that no terms, conditions, or stipulations additional to those contained in the Tender Documents have been imposed by the issue of this letter. Signature & Stamp ……………………………………… …………………………………………… (Contractor) (Witness) Name : ………………………………… Name : ………………………………… I.C. No. : ………………………………. I.C. No. : ………………………………. Address : ……………………………… …………………………………………. …………………………………………. …………………………………………. …………………………………………. …………………………………………. Date : ………………………… Date : …………………………

BANK GUARANTEE FOR PERFORMANCE BOND (WORKS)

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BANK GUARANTEE FOR PERFORMANCE BOND (WORKS)

THIS AGREEMENT is made the ………………… day of ……………………… 20 ……………

BETWEEN ……………………………………………………………………………………………

(insert name of Bank) of ……………………………………………………………………………. (insert principal address of business of Bank) (hereinafter called “The Guarantor”) of the one part and Swinburne University of Technology Sarawak (SUTS) (hereinafter called the “Employer”) of the other part. WHEREAS

In consideration of the Employer allowing ……………..

…………………………………………………………… (hereinafter referred to as “the Contractor”) to Construct and Complete the Proposed Construction And Completion Of The Construction and Completion of the Proposed Expansion Plan of Swinburne University of Technology Sarawak (SUTS) at Jalan Uplands for a contract sum of Ringgit Malaysia ………………………………………………………………………….. (RM ) …………………………………………………………………… ……………………… We, the undersigned at the request of the Contractor irrevocably undertake a guarantee to the Employer that:-

The Guarantor has agreed to guarantee the due performance of the said Contract in

the manner hereinafter appearing. NOW the Guarantor hereby agrees with the Employer as follows:-

1. On the Employer’s first written demand, the Guarantor shall forthwith pay to the Employer the amount specified in such demands not withstanding any contestation or protest by the Contractor or Guarantor or by any other third party and without proof or conditions. Provided always that the total of all demands so made shall not exceed the sum of

Ringgit Malaysia ………………………………………………………………………………

…………………………………………………………………………………………………

(state the amount of bond in words) (RM …………………………) and the total amount recoverable against the Guarantor under this Agreement shall not exceed the said sum.

2. The Employer reserves the right to make any partial demands if it shall so desire and

the total of all such partial demands so made shall not exceed the sum of Ringgit Malaysia

…………………………………………………………………………………………………

……………………………………………………………………(state the amount of bond

in words) (RM ………………………………) and the liability of the Guarantor to pay SC the aforesaid shall correspondingly be reduced proportionate to any payment of partial demands having been made by the Guarantor.

3. The Guarantor shall not be discharged or released from this Guarantee by any

arrangement between the Contractor and the Employer with or without the consent

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of the Guarantor or by any alteration in the obligations undertaken by the Contractor or by any forebearance whether as to payment, time, performance or otherwise.

4. The guarantee given by the Guarantor is a continuing guarantee. This Agreement shall be irrevocable and shall initially remain in force and effect until ………………………… (hereinafter referred to as the “Initial Expiry Date”) being the end of a period of twelve (12) calendar months after the expiry date of the defects liability period as stated in the contract or in the case of the Contract being determined, one (1) calendar year after the date of determination. The Guarantor shall upon the request of the SC extend the Initial Expiry Date of this guarantee for a further period of one (1) calendar year from the Initial Expiry Date (hereinafter referred to as the “Extended Expiry Date”) and the Guarantee shall be so extended. The maximum aggregate amount that the Employer shall be entitled to under this

Agreement shall not exceed the said Sum of Ringgit Malaysia …………………………

………………………………………………………………………………………………….

(state the amount of bond in words) (RM ……………………………). 5. All whatsoever obligations and liabilities of the Guarantor under this Agreement shall

cease upon the determination of this Agreement on the Initial Expiry Date or the Extended Expiry Date as the case may be save to the extend that the Employer shall previously have called upon the Guarantor in writing to pay specified monies payable under the contract then remaining outstanding.

6. All claims, if any, in respect of this guarantee must be received by the Bank during

the validity period of this Guarantee or within four (4) weeks from the expiry date of this Guarantee whichever is the later.

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IN WITNESS WHEREOF the parties hereto set their hands the day and year first above written. Signed for and on behalf of the said ) Guarantor ) ……………………………………………… Name …………………………………….. Designation ………………………………. Bank’s Seal ………………………………. in the presence of ……………………………………………… (Witness) Name ………………………………………. Designation ………………………………… Signed for and on behalf of the said ) Swinburne University of Technology ) ……………………………………………… Sarawak (SUTS) Swinburne University of Technology

Sarawak (SUTS) ……………………………………………… Company Chop in the presence of ……………………………………………… (Witness) Name ………………………………………. Designation …………………………………

PREAMBLE TO SUMMARY OF TENDER

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SUMMARY OF TENDER PREAMBLE

1.0 LUMP SUM CONTRACT This is a Lump Sum Contract in which the Summary of Tender is to be read in

conjunction with the Conditions of Contract, the Specifications and the Drawings. The Schedule of Rates shall be used only for the ascertainment of prices for Variation Orders. The Tenderers is responsible for obtaining his own quantities from the Drawings and insert in the Summary of Tender and takes responsibility for their accuracy.

2.0 CONTRACTOR’S ACQUAINTANCE The Contractor shall be deemed to have acquainted himself with the detailed

description of the works to be carried out the manner in which they are to be executed and the requirements and standards of the completed works. General directions and description of works and materials given in the Specifications are not necessarily repeated in the Summary of Tender. Reference must be made to the Specifications and Drawings for the information.

3.0 ITEMS GIVEN The items set forth in the Summary of Tender shall, except insofar as may be

otherwise expressly provided in the Contract, be deemed to cover all the Contractor’s liabilities and obligations set forth or implied in the Contract and all matters and things necessary for the proper construction, completion and maintenance of the works.

4.0 OVERHEADS AND PROFITS, ETC. Overheads, profits, etc. shall be deemed to be included in the rates, prices, sums

etc. in the Summary of Tender and Schedule of Rates. 5.0 SAMPLE TESTS The Contractor shall be deemed to have allowed in the sums in the Summary of

Tender for complying with and for carrying out all necessary trials, tests and taking all necessary samples for testing by the Engineer as described in the Specifications and/or indicated on/or inferred from the Tender Documents unless otherwise specified.

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6.0 TEMPORARY WORKS The Contractor shall be deemed to have allowed in the Summary of Tender for the

provision, maintenance and final removal of all temporary works of whatsoever nature required for the proper execution of the works. No further specific items of particular temporary works will be measured separately.

7.0 PROVISION, TRANSPORT REMOVAL OF PLANT Payment for the provision, transport and removal of any item of plant engaged upon

the Works shall be included in the Summary of Tender. 8.0 UNSUITABLE PLANT If during the execution of the Works any item of plant should in the opinion of the

Engineer prove to be unsuitable or out of repair so as to fail to perform the service required in the execution of the Works, the Contractor shall replace such plant with other suitable plant at his own cost and until the replacement has been satisfactorily made, the Employer may withhold from subsequent payments as sum representing such portion of the monies as the Engineer shall certify to be reasonable.

9.0 DELAYS DUE TO WEATHER When selecting his equipment, the Contractor shall make due allowances for the

nature of the Site and for the weather condition which can occur there. No payments will be made on account of any claims for delays due to bad weather conditions.

10.0 PRICE OF ITEMS Every item shall be rated or priced but no new items shall be added. If any item is

not prices, it shall be deemed to be covered by the other priced items in the Summary of Tender.

11.0 PAYMENT Payment against such Lump Sum items shall be paid in proportion to the extent of

which at the end of the period in question, in the opinion of the Engineer, the relevant services have been provided or as stipulated in the Specifications.

12.0 CONTINGENCY AND PROVISIONAL SUMS The amount under Provisional and Contingency Sums shall be expended in the

whole or in part or not at all as the Engineer may direct. Where work to which a Provisional Sum relates has been ordered by the Engineer and has been executed by the Contractor the work as executed will be valued in accordance with Clause 33 of the Conditions of Contract.

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Items of Work under Provisional items, when instructed, shall be paid at the rates inserted for the appropriate items in the Summary of Tender (whether the quantities instructed are lower or higher than quantities stated). If no work of any item is instructed to be executed, then the total amount inserted in that item of the Summary of Tender shall not be payable.

Rates shall allow for time cost associated with the work and no extension of time or

delay costs will be considered or granted unless the Contractor demonstrates that the extension of such work in excess of the provisional quantities shown was on the critical path and caused a delay to the completion of the project.

All provisional quantities will be subject to joint measurement prior to payments. All costs of and related to the joint measurements and valuations of the Works shall

be deemed to be included in the respective items in the Summary of Tender. 13.0 SITE VISIT Tenderers will be deemed to have inspected the Site of the Works before submitting

their Tenders. Tenderers must make, or cause to be made on their behalf, local enquiries

concerning the availability and cost of any plant required, accommodation, labour, temporary supplies of power, water supply, access and all other local conditions and matters affecting the Tender.

Tenderers shall obtain for themselves on their own responsibility all other information

which may be necessary for making a tender and entering into contract and must examine the Tender Documents in order to ascertain the matters as to which they will be deemed to have satisfied themselves and the risks and obligations which they are to undertake.

Tenderers may, at their own expense, make additional site investigations if they so

desire. 14.0 SUB-LETTING Details and particulars of sub-letting and sub-contractors proposed for the Works

shall be inserted in the Appendices to the Summary of Tender. In the event that a tenderer is accepted, he shall not sub-contract any works to any other contractors without the approval of the Employer.

15.0 VARIATION ORDER Any variation as ordered based on the Schedule of Rates will in no way void or abate

the conditions or provisions of the Contract or relieve the Contractor from the responsibility of constructing the work to the required standard and carrying out the maintenance specified. Any additional labour, transport or material required to make good faulty work or used in repair or maintenance will be at the expense of the Contractor and will not be taken into the account when determining the sum to be paid for each item or section of the works.

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16.0 PRICES IN MALAYSIAN RINGGIT All items in the Summary of Tender and Schedule of Rates shall be priced in

Malaysian Ringgit.

SUMMARY OF TENDER

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THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF TECHNOLOGY

SARAWAK AT JALAN UPLANDS

SUMMARY OF TENDER DESCRIPTION RM CT 1. PRELIMINARIES AND GENERAL

Mobilization, Insurance, Site preparation, Site office, Performance bond and Deposit.

2. PILING WORKS (PROVISIONAL QUANTITY)

350 MM DIAMETER PRE-CAST PRESTRESSED CONCRETE SPUN PILE A. Supply, handle and transport 350mm Diameter pile. B. Pitch and drive 350mm Diameter pile to required set. C. Cutting off head of 350mm Diameter pile at required level. D. Provide all materials, labour, plan, tools and all the necessary instruments for carrying out static load test. 100 MM DIAMETER BAKAU PILE A. Supple, handle, and transport 100mm Diameter pile. B. Pitch and drive 100mm Diameter pile to required set. C. Cutting off head of 100mm Diameter pile at required level. STEEL SHEET PILE PILING EQUIPMENT

3. BUILDING WORKS 2 BLOCKS OF 5-STOREY HOSTELS

CAFETERIA MULTI-STOREY PARKING LOTS M&E WORKS

ST-2

4. EXTERNAL WORKS A. Fencing and gate as shown and/or specified.

B. Surface water drainage comprising drains, culverts, perimeter drains and all associated works as shown and/ or specified. C. Man-made lake D. Landscaping Works

6. CONTINGENCY SUM 250,000 .00 5. ANY OTHER ITEMS OF WORK

Any other items of work not specifically mentioned but are deemed necessary for the satisfactory completion of the building works. i. ii. iii.

TOTAL SUM CARRIED TO FORM OF TENDER

SCHEDULE OF RATES

SR-1

Item Description

Unit Amount

RM Sen

Abbreviation M - Meter M2 - Square meter KG - Kilogram M3 - Cubic meter NO - Number C/W - Complete with HDPE - High Density Polyethylene A EXCAVATOR

A1

Excavate for foundation, trenches, ground beams, manholes, etc. not exceeding 1.50m deep and get out, part backfill around foundations and remainder remove, deposit and consolidate in 150mm layers in making up levels

M3

A2 Ditto exceeding 1.50m and not exceeding 3.00m deep ditto

M3


M3

A4 Ditto not exceeding 1.50m deep and get out, part backfill around foundations and remainder remove from site to Contractor’s own dump

M3


M3


M3

A7 Extra over excavation for excavating in hard rock and remove off the site

M3

A8 Approved imported sand-filling to be obtained from the Contractor’s own sources, and deposit, spread and consolidate in making up levels

M3

SR-2

A9 Approved imported earth-filling to be obtained from the Contractor’s own sources, and deposit, spread and consolidate in 150mm layers in making up levels

M3

A10 300mm ditto M3

A11 Approved imported top soil-filling to be obtained from the Contractor’s own sources, and deposit, spread and consolidate in 150mm layers in making up levels

M3

A12 100mm thick bed of approved hardcore as described, well compacted, watered and consolidated, blinded on top with sand to receive concrete

M2

A13 150mm thick bed of approved hardcore as described, well compacted, watered and consolidated, blinded on top with sand to receive concrete

M2

A14 150mm thick approved 38mm down crushed run as described, well compacted, consolidated, to receive blockstone riprap

M2

A15 300mm thick blockstone riprap with cement sand mortar as described

M2

Anti-termite

A16 ‘LENTREK (*) 400EC INSECTICIDE’ or other equal and approved anti-termite chemical treatment to sub-structure of building all in accordance with the Manufacturer’s Instruction

M2

B CONCRETOR

B1 50mm thick lean concrete Grade 15 as specified blinding

M2

SR-3

B2 75mm thick lean concrete Grade 15 as specified blinding

M2

B3 Mass concrete Grade 20 as specified M3

B4 Mass concrete Grade 30 as specified M3

B5

Vibrated reinforced concrete Grade 20 in pad footings, pile cap, stump, beams, column stump, columns, slab, drain, culverts, manhole, sumps etc. as specified filled into formwork and well packed around reinforcement (formwork and reinforcement measured separately)

M3

B6 Vibrated reinforced concrete Grade 25 ditto M3



B9 Formwork ‘Type F1’ as specified to pad footings, pile cap, stump, beams, column stump, column, slab, drain, culverts, manholes and sumps, etc.

M2

B10 Formwork ‘Type F2’ as specified to beams, column stump, column, slab, drain, culverts, manholes and sump, etc.

M2

B11 1 layer of ‘Polythene Grade 500’ or other equal and approved damp proof membrane as specified laid under ground slab

M2

B12 ‘Acrylic Polymer FOSROC Brushbond’ or other equal and approved cement waterproofing system laid to ground floor slab including all necessary upturn

M2

Mild steel bar reinforcement as specified inclusive of bending and placing into position:-

B13 6mm to 8mm diameter KG


SR-4


High yield steel bar reinforcement as specified inclusive of bending and placing into position:-



Fabric Mesh Reinforcement

B18 BMC No. A6 mesh reinforcement well lapped at joints and embedded in concrete (measured nett and no allowance made for laps)

M2

B19 Ditto A7 all as before described M2



B22 Ditto A10 all as before described M2 Sundries

B23 Floor hardener with ‘SIKA Chapdur Premix’ non-metallic at 6kg/m2 or equivalent

M2

B24 Expansion joint with ‘FOSROC Thioflex 600’ or equivalent with approved resin bonded cork filler, rubber water stop with central bulb, PVC capping strip, etc. all as per detail drawing

M

B25 100mm diameter UPVC discharge pipe including all necessary excavation and backfilling

M

B26 50mm diameter PVC discharge pipe including filter cloth, 20mm diameter aggregates, etc. all as per detail drawing and all necessary excavation and backfilling

NO

C BRICKLAYER

SR-5

C1 75mm Thick brickwall in cement mortar and reinforced with

M2

C2 115mm Thick ditto M2

C3 230mm Thick ditto M2

C4 Approved bituminous felt damp proof course as described on brick walls, 75mm wide

M

C5 Ditto, 115mm wide M

C6 Ditto, 230mm wide M

C7

6mm Diameter mild steel bonding lie, 455mm girth hooked at both ends with one end cast into concrete structure and the other end built into brickwork including perforation through formwork

NO

D PAVIOUR

D1 20mm Thick cement and sand (1:3) paving as specified, trowelled smooth

M2

D2 Ditto to tread of step, 275mm wide M

D3 Ditto to undercut riser of step, 180mm high M

D4 Extra over for forming approved herringbone groove line

M2

D5

300mm x 300mm "GUOCERA DV962" or other equal and approved homogeneous tile of approved colour and pattern laid and jointed in approved cement mortar (1:3) on and including 20mm thick cement and sand (1:3) screed and pointed with approved coloured cement to match

M2

D6 300mm x 300mm "GUOCERA DRE02" or other equal and approved non-slip homogeneous tiles all as before described

M2

D7 200mm x 200mm "GUOCERA DRE02" or other equal and approved non-slip homogeneous tiles all as before described

M2

D8 Extra over for "GUOCERA" or other approved non-slip nosing tile

M

SR-6

D9

Supply and lay "Baiduri Width 12" of other equal and approved anti-static carpet of approved colour and pattern laid on and including approved underlay and adhesive all to Manufacturer Detail

M2

Waterproofing

D10

"Acrylic Polymer FOSROC Brushbond" or other equal and approved cementitious waterproofing system as described laid to suspended floor slab

M2

D11 Ditto to upturn, 150mm high M E ROOFER

E1

"Lysaght Spandek 0.47mm TCT in Clean Colorbond Steel (G550-AZ150) or other equal and approved metal roofing sheet of approved colour fixed on approved C-purlin channel (measured seperately) including all necessary fixing accessories all in strict accordance with Manufacturer's Instructions (Measured nett and no allowance made for laps)

M2

E2 Extra over for Standar barge capping M

E3 Extra over for Standard metal fascia capping M

E4 Extra over for L-shape end piece NO

E5 Extra over for Standard 3-Way Apex NO


E7

"Lysaght Spandek 0.47mm TCT in Clean Colorbond Steel (G550-AZ150) or other equal and approved metal roofing sheet of approved colour fixed on and including approved hardwood batten and all necessary fixing accessories all in strict accordance with Manufacturer's Instructions (Measured nett and no allowance made for laps)

M2

E8 Extra over for Standard ridge capping M

E9 Extra over for Standard hip capping M

E10 Extra over for Standard hip starter NO

E11 Extra over for Standard ridge starter NO


SR-7


E14

Approved galvanized iron partywall flashing once bend to shape to a total girth of 300mm with one end built into brick/ concrete work and the other end dressed over roof tiles including fixing accessories and painting

M

Insulation

E15

One layer of "UB-Foil 102" or other equal and approved double sided aluminium reflected foil laid to fall on and including approved wire mesh (measured nett and no allowance made for laps)

M2

E16

One layer of 50mm Thick "Roxul Stone Wool" or other equal and approved insulation quilt with nominal density of 40 kg/m3 laid to fall (measured nett and no allowance made for laps)

M2

Rainwater Goods

E17 100mm Diameter UPVC rainwater down pipe encased into concrete column

M

E18

100mm Diameter UPVC rainwater down pipe laid underground including all necessary excavation, backfilling and forming opening through concrete beam and connection to drain

M

E19 Extra over 100mm Diameter UPVC rainwater down pipe for bend

NO

E20

100mm Thick approved clean colorbond gutter bend to shape to a total girth of 1000mm complete with approved bracket including all necessary fixing accessories al as per detail drawing

M

E21 Extra over gutter for stop ends NO

E22 Labour and material for forming 100mm diameter outlet through gutter including approved grating cover and approved sealant

NO

F CARPENTER AND JOINER

F1 Sawn Grade 'B' timber in nogging, stud, joist, rafter, strut, packing piece, etc.

M3

F2 Wrot Grade 'A' timber in beam, joist, flooring, fascia, board, door framing, etc.

M3

SR-8

Ceiling framing and finishing

F3

3.2mm Thick “UAC” or other equal and approved cemboard ceiling lay on and including approved galvanized mild steel channel, approved hardwood beading and cornices and all necessary of the room

M2

F4 Ditto exceeding 3.50m and not exceeding 5.00m high

M2

F5

3.2mm Thick “UAC” or other equal and approved cemboard eave soffit lay on and including approved hardwood noggin, approved hardwood beading and cornices and all necessary fixing accessories

M2


M2

F7

10mm Thick approved gypsum board ceiling with tape joint in fibre tape lay on and including approved galvanized mild steel channel and all necessary fixing accessories

M2


M2

F9 Extra over for forming 750mm × 750mm access panel through UAC cemboard ceiling with and including all necessary framing

NO

F10

Suspended “CASOLINE GRID” or approved equivalent ‘T’ bar ceiling system with “CASOPRANO” ceiling tiles or equivalent, all to manufacturer’s details including all necessary fixing accessories

M2

DOOR FRAMING AND FINISHING OF APPROVED TIMBER AS DESCRIBED INCLUDING DOOR FRAMES, PAINTING ANF HUNG DOOR ON BUTT HINGES (IRONMONGERY MEASURED SEPERATELY) ALL AS PER DETAIL DRAWING

For Office cum Workshop

F11 Type D1 NO

F12 Type D2 NO

F13 Type D3 NO

SR-9

F14 Type D4 NO

F15 Type D5 NO

F16 Type D6 NO

For Guard House

F17 Type D1 NO

F18 Type D2 NO

SUPPLY AND FIX APPROVED FIRE RATED DOOR AND FRAME ALL TO MANUFACTURE’S DETAILS IN COMPLIANCE WITH JABATAN BOMBA (m) REQUIREMENTS AND ENGINEER’S APPROVAL INCLUDING ALL NECESSARY INTUMECENT STRIP AND APPROVED PAINTING SYSTEM

F19 ‘MULTEC (AQO)’ or approved equivalent one hour fire rated door (Type FD1)

NO

F20 ‘MULTEC (AQO)’ or approved equivalent one hour fire rated door (Type FD2)

NO

G IRONMONGERY

G1

Install only for the following or other equal and approved ironmongery including providing requisite matching screws and fixed to hardwood or set in concrete floor

NO

G2 TREX 100mm × 75mm × 2mm stainless steel Hinges (H1)

NO

G3 TREX 100mm × 75mm × 2mm stainless steel Hinges (H2)

NO

G4 SURE-LOC 780US32D-510-60-TT-AQO Lockset (L1)

NO

G5 SURE-LOC F16-513US32D-40-AQO Lockset (L2) NO

G6 SURE-LOC CA3807US32D-60-AQO Lockset (L3) NO

G7 SURE-LOC CA3802US32D-60-AQO Lockset (L4) NO

G8 RAM 802-SB DOOR Closer (C1) NO

SR-10

G9 RAM 802-SB DOOR Closer (C2) NO

G10 SURE-LOC ML Stainless Steel Rebated Set (R1) NO

G11 TREX Stainless Steel Flush Bolt 150 & 300mm (A1) NO

G12 TREX 1729A Stainless Steel Coat Hook (A2) NO

G13 TREX 1729B Stainless Steel Door Stopper (A3) NO

G14 TREX 532CP Door Stopper (A4) NO

G15 TREX T-350 Stainless Steel Door Selector (A6) NO

G16 TRAX AFB-AQO Automatic Stainless Steel Flush Bolt (A7)

NO

G17 TS-MG-250 Stainless Steel Flush Bolt (A7) NO

G18 Master Keying Allowance NO

H STEEL AND IRON WORKERS

H1

Hot dip galvanized mild steel stanchion, beams, roof trusses, channel, joists, posts, angle, hollow section, plates, cleats, purlins, etc. in structural steelwork all welded and bolted together including all shop and site work, fabrication, transportation, erection, surface preparation, welding, filling smooth junction and complete with approved primer before fixing and fixed in position

KG

H2

Mild steel stanchion, beams, roof trusses, channel, joists, posts, angle, hollow section, plates, cleats, purlins, etc. in structural steelwork all welded and bolted together including all shop and site work, fabrication, transportation, erection, surface preparation, welding, filing smooth junction and complete with Blast-Cleaned to SA 2 ½ Swedish Standard SIS 05-5906 with one layer Exoxy primer and two finishing coats of aplihatic urethane or approved equivalent before and after fixing and fixed in position

KG

Mild steel bolt Grade 8.8 complete with head, nut and washers including drilling through hardwood or metal

H3 M12 bolt, 200mm long NO


SR-11




Mild steel bolt Grade 8.8 complete with head, nut and washers including drilling through hardwood or metal, with one end cast into concrete complete with grouting on cement and sand (1:3)



H10 M16 Bolt, 400mm long NO

H11 M20bolt, 300mm long NO

H12 M24 Bolt, 300mm long NO

SUPPLY AND INSTALL NATURAL ANODDISED ALUMINIUM WORK IN EXTRUDED SECTIONS AS DESCRIBED COMPLETE WITH APPROVED 6MM THICK GREEN TINTED GLASS,SILICONE SEALANT,MASTIC POINTING AND CLEANING DOWN ON COMPLETION AS PER DETAIL DRAWINGS

For office cum workshop

H13 Type W1 NO

H14 Type W2 NO

H15 Type W3 NO

H16 Type W4 NO

H17 Type W5 NO

H18 Type W6 NO

H19 Type W7 NO

H20 Type W8 NO

SR-12

For Guard house H21 Type W1 NO

H22 Type W2 NO

H23 Type W3 NO

I PLASTERER AND WALL TILER I1 13mm Thick external plastering as specified M2 I2 19mm Ditto M2 I3 13mm Thick internal plastering as specified M2 I4 19mm Ditto M2 I5 4mm Thick approved plaster skim coat as specified M2

I6

200mmX250mm GUOCERA F186A or other equal and approved glazed ceramic wall tile of approved colour and pattern bedded and jointed in approved cement mortar(1.3) on and including 20mm.Thick cement and sand (1.3) screed and pointed with approved coloured cement to match

M

I7 Extra over plastering for forming 25mmX10mm approved groove line as per detail drawing

M2

J PLUMBER

Supply and fix medium duty coated cast iron soil, waste or ventilation pipe complying with BS416 including spigot and socket joints

J1 50mm Diameter M2 J2 75mm Diameter M2 J3 100mm Diameter M2 J4 150 Diameter M2 Extra over for fittings with inspection opening

J5 50mm Diameter bend/elbow NO J6 75mm Diameter ditto NO J7 150mm Diameter ditto NO J8 50mm X 50mm X 50mm Diameter tee NO J9 75mm X 75mm Diameter tee NO J10 100mm X 100mm X 100mm Diameter tee NO J11 150mm X 150mm X 150mm Diameter tee NO

SR-13

Supply and fix unplasticised polyvinyl chloride soil, waste or ventilating pipe complying with BS4514 and 5255 with solvent cement joint including all short length, couplings, tees, bends, elbows etc

J12 20mm Diameter M J13 40mm Diameter M J14 50mm Diameter M J15 80mm Diameter M J16 100mm Diameter M J17 150mm Diameter M

Cold Water Services

Supply and install for the following or other equal and approved sanitary fittings in complete set including sorting. Assembling, bedding, plugging, screwing, priming, fixing accessories and making good disturbed area and connecting to services all in strict accordance to the Manufacture’s Details and Instructions

J18 “SAMA” BA804 Vanity Wash Basin c/w 1 1/4 “ plug & chian waste

NO

J19 “SAMA” BA803 wall hung basin c/w 1 ¼ “plug chain & chain waste

NO

J20 “BRAVO” HM872A Basin Tap NO

J21 “SAMA” NC201S Low Level Wash Down WC c/w High Level Plastic Tank

SET

J22 “SAMA” SQ31S Squatting Pan c/w High Level Plastic Tank

SET

J23 “SAMA” AC10 Toilet Paper Holder NO

J24 “BRAVO” HM871C Wall Trap NO

J25 “BRAVO” 6” Stainless Steel Flour Grating NO

J26 “SAMA” BA803 wall hung basin & 1 ¼ “plug chain & chain waste

SET

J27 “CAM” 38” X 42” Aluminium Sink c/w 1 ½ Waste NO

SR-14

J28 “BRAVO” S3034DA Sink Tap NO

Approved grating to suit floor trap set flush with floor finish

J29 Approved 150mm X 150mm square stainless steel floor strainer / trap including grating cover with one inlet and one outlet

NO

GLAZIER

K1

6mm Thick green tinted glass and glazing to wood or metal as specified not exceeding 0.50m super M2

K2 Ditto exceeding 0.50m and not exceeding 1.00m super M2


K4 Ditto exceeding 1.50m and not exceeding 2.00m

M2

K5

6mm Thick tinted frosted glass and glazing to wood or metal as specified not exceeding 0.50m super. M2




M2

K9

6mm Thick tinted sheet glass and glazing to wood or metal as specified not exceeding 0,50m super M2




M2

L PAINTER

SR-15

Prepare and apply “ICI” or other equal and approved paint system of one coat of “ICI Dulux A931 – 18177” alkali resisting wall primer and two finishing coats of “ICI Dulux A910 – Line” exterior finish fungal resisting paint of approved colour externally on surfaces of

L1 Plastered sides of wall with associated column and beam M2

L2 Plastered sides of isolated column M2

Prepare and apply “ICI” or other equal and approved paint system of one coat of “ICI Dulux A931 – 18380” wall sealer and two finishing coats of “ICI Maxilite Plus A919 – Line” emulsion paint of approved colour internally on surfaces of

L3 Plastered sides of wall with associated column and beam M2

L4 Plastered side of the isolated column M2 L5 Plastered ceiling M2

L6 Plastered ceiling exceeding 3.50m and not exceeding 5.00m high (measured flat overall) M2

L7 UAC cemboard ceiling (measured flat overall) M2

L8 Ditto exceeding 3.50m and not exceeding 5.00m high (measured flat overall) M2

L9 UAC cemboard eave soffit (measured flat overall)

M2

L10 Ditto exceeding 3.50m and not exceeding 5.00m high (measured flat overall) M2

L11 Gypsum board ceiling M2

L12 Ditto exceeding 3.50m and not exceeding 5.00m high M2

Prepare, knot, prime, stop and apply “ICI” or other equal and approved paint system of one coat “ICI A519 – 3697” aluminum wood primer, one coat of “ICI Dulux Speed undercoat A543 – 101” undercoat and two finishing coats of “ICI Dulux Gloss Finish A365 – Line” gloss paint of approved colour externally on timber surfaces

L13 Hollow core door (measured flat overall) M2 L14 Solid core door (measured flat overall) M2

SR-16

L15 General surfaces of door frame not exceeding 100mm girth M

L16 Ditto exceeding 100mm and not exceeding 200mm girth M


Prepare, knot, prime, stop and apply “ICI” or other equal and approved paint system of one coat “ICI A519 – 3697” aluminum wood primer, one coat of “ICI Dulux speed undercoat A543 – 101” undercoat and two finishing coats of “ICI Dulux Gloss Finish A365 – Line” gloss paint of approved colour internally on timber surfaces.

L18 Hollow core door (measured flat overall) M2 L19 Solid core door (measured flat overall) M2

L20 General surfaces of door frame not exceeding 100mm girth M



M SITE CLEARANCE

M1

Clear area within the whole lots boundary of tall shrubs and superfluous vegetation, remove all fallen tree trunks, tree stumps etc. Cut down existing trees irrespective of growth and girth and grub up roots and remove debris from site.

M2

M2

Excavate and remove the topsoil average 500mm thick to Contractor’s own dumping ground as directed

M3

N EARTHWORKS

N1 Selected imported sand filling to required level in approved layers well compacted M3

N2 Extra over for forming embankment and trimming to slope as specified M2

N3

300mm thick selected imported earthfill (with minimum 15% clay content) to form earth bund including embankments and trimming to form slope as directed

M2

SR-17

N4

Selected imported earth filling well compacted to from earth bund including forming embankment and trimming to form slope M3

O ROAD AND CARPARK

O1

Excavate oversite for road sub‐base to required level, get out and cart away from the site. M3

O2

Labour for trimming, leveling, grading and rolling sub‐grade to required gradient, chambers, curves and crossfalls to an even surface with an approved road roller.

M2

O3

300mm thick selected imported earthfill well compacted as specified to form road shoulder as directed.

M2

O4

200mm thick sub‐base course as described of 50mm diameter down crusher run stone laid to required falls, slopes and chambers and rolled with an approved road roller.

M2

O5

250mm thick road base as described of 38mm diameter down crusher run stone laid to required falls, slopes, chambers and rolled with an approved road roller.

M2

O6

50mm thick premix wearing course as described, spread and leveling to the required falls, slopes or chambers and rolled with an approved road roller. M2

O7 A layer of primer coat as described M2

O8 600mm widex150mm high subsoil drain constructed of

approved 50mm down crusher run stone, wrapped all round

with 'KSG 20' or other equal and approved filter cloth and all M

necessary excavation and backfilling.

P ROAD MARKING

Prepared and apply 2 coats of approved thermoplastic road

paint system as described all as per drawing

P1 100mm wide broken carriageway centre line M

SR-18

P2 100mm wide broken carriageway centre line curved on plan

to varying radii M

P3 150mm wide unbroken carriageway edge line M

P4 150mm wide unbroken carriageway edge line curved on

plan to varying radii M

P5 300mm wide stop line M

P6 185mm wide(minimun) and 825mm wide(maximum)

straight directional arrow approximately 3000mm long M


double head turning directional arrow approximately

1570mm long NO


single head(left/right) turning directional arrow

approximately 1570mm long NO

P9 Straight cum one single head turning directional arrow

comprising 185mm wide(minimun) and 825mm wide

(maximum) straight directional arrow approximately

3000mm long and 1120mm wide single head turning

directional arrow approximately 1835mm long NO

Q ROAD SIGN

The following road signs with Retroreflective of Engineering

Grade on 5mm thick aluminium sheets with approved

lettering and colour and comply with requirement of JKR's

SR-19

Arahan Teknik (Jalan) 2A/85, as per detail drawing

Q1 BERHENTI' symbol in hexogan shape pverall size

900mmx900mm (Type RP.1) NO

Q2 NO ENTRY FOR ANY VEHICLE' symbol in circle shape overall

diameter 750mm (Type RP.4) NO

R RC DRAIN (EXCLUDING PILING) NO

Reinforced Concrete Grade 25 Cast‐In‐Situ 'U' Shaped Drain

Constructed of HRPC Channel, Grade 25 Concrete,

Reinforcement and Formwork as described as per detail

drawing

500mm Wide (Internal) Drain

R1 Average 300mm deep to invert M










R11 Extra over for forming 50mm x 120mm high rebated edges

to drain wall to receive drain cover(measured separated) M

SR-20

500mm Wide(internal) Cascading Drain


500mm Wide(internal) Drain Curved on Plan to Varying Radii



S PC COVER

S1 Overall size 600mm wide x 600mm long x 125mm thick Grade

25 heavy duty precast concrete drain cover reinforced with

two layers of BMC A9 mesh reinforcement including forming

opening and place in position NO


25 heavy duty precast concrete drain cover reinforceced with

two layers of BMC A9 mesh reinforcement including forming

opening and place in position NO


25 precast concrete drain cover reinforceced with two layers

of BMC A9 mesh reinforcement including forming opening

and place in position NO

7 EARTH DRAIN

Excavate for earth drain including forming embankment,

trimming shape, gading surfaces, disposal of excavated

SR-21

material off site to Contractor own dumping ground

T1 With top width from 3320mm(minimum) to 3830mm

(maximum) and bottom width fixed at 500mm wide, average

1025mm deep to invert M
















U CULVERT (EXCLUDING PILING)

Precast Concrete Class 'Z' or other Equal and Approved Pipe

Culvert Laid on Concrete Grade 30 Base, Wing Wall, Benching

SR-22

,Lean Concrete, Reinforcement, Formwork as Described all as

per Detail Drawing

U1 1200mm diameter x 2000mm deep to invert x 11850mm long NO

Approach Slab

U2

9000mm x 2500mm x 225mm thick reinforced concrete Grade 30 approach slab laid on and including 50mm thick lean concrete including reinforcement, formwork, approved finishes and all necessary excavation, backfilling and cart away surplus all as per drawing

NO

Stone Pitching

U3

Supply and fix in position approved 225mm thick grouted stone pitching to suit site and design including all necessary excavation and cart away from site all as per detail drawing

M2

HDPE Flap Valve

U4

Supply, transport, inspect, handle and fix in position 1200mm diameter HDPE flap valve complete with back plate, sealing tape and all fittings and accessories all in strict accordance to Manufacturer’s details and instruction

NO

Reinforced Concrete Grade 30 Cast-In-Situ Twin Box Culvert Constructed of HRPC Channel, Grade 30 Concrete, Reinforcement, Formwork as Described all as per Detail Drawing

U5 7050mm wide x 2275mm (internal) deep to invert x 2030mm long NO

Block stone Rip Rap

U6

Supply and fix in position approved 300mm thick block stone rip rap in 1:3 cement sand mortar laid on and including 150mm thick bed of approved 38mm diameter down crushed run, all necessary excavation and cart away surplus all as per detail Drawing

M2

Reinforced Concrete Grade 25 Cast-In-Site Sump Constructed of Grade 25 Concrete, Reinforcement, Formwork as Described all as per Detail Drawing

1500mm x 1000mm (internal size) sump

U7 Average 1700mm deep to invert NO

SR-23

V FOUL DRAINAGE (EXCLUDING PILING)

Approved 150mm diameter UPVC pipes and fittings to BS 4514 jointed with and including approved joints and laid in trench in accordance with Manufacturer’s Instruction

V1

150mm diameter soil pipe with and including 450mm x 450mm deep Grade 25 concrete surround laid on and including 50mm thick lean concrete blinding including all necessary excavation, backfilling and cart away surplus from site.

M

V2

150mm diameter effluent pipe with and including 450mm x 450mm deep Grade 25 concrete surround laid on and including 50mm thick lean concrete blinding including all necessary excavation, backfilling and cart away surplus from site.

M

Brick Manhole Constructed of Concrete Grade 25 Base and Suspended Slab including Reinforcement, Sawn Formwork, Brick Wall with Cement and Sand (1:2) as Described all as per Detail Drawing

600mmx450mm (internal size manhole)

V3 Average 450mm deep to invert level NO V4 Average 530mm deep to invert level NO Manhole Cover

V5 Approved 600mm x 450mm cast iron manhole cover and frame and place in position NO

W SEPTIC TANK (EXCLUDING PILING)

W1

Supply, delivery, install, testing and commissioning of Polysept PS-3’ or other equal and approved septic tank, complete with inlet and outlet manhole chamber internal size 600mm x 450mm, as per detail drawing

NO

W2

Supply, delivery, install, testing and commissioning of the Polysept PS-40Cl’ or other equal and approved septic tank, complete with inlet and outlet manhole chamber internal size 600mm x 450mm, as per detail drawing

NO

X FENCING AND GATE (EXCLUDING PILING)

SR-24

X1

2600mm high PVC coated chain link fencing consisting of 50mm mesh No.8 SWG PVC coated wire chain link 2100mm high, as per detail drawing M

X2 Chain Link Gate overall size 6000mm x 2600mm high as per detail drawing NO

Y TURFING Y1 Prepare and clear the whole area to be turfed M2

Y2

150mm thick layer of approved black vegetable soil well mixed with rock phosphate fertilizer at the rate of 11gm per square meter spread and leveled on flat or slightly sloping area

M2

Y3

150mm thick layer of approved black vegetable soil well mixed with rock phosphate fertilizer at the rate of 11gm per square meter spread and leveled on slopping area

M2

Y4

Spot turfing with approved turves including all necessary watering, rolling, weeding, tending and maintenance until firmly established to flat or slighty sloping area

M2

Y5

Close turfing with approved turves including all necessary watering, rolling, weeding, tending and maintenance until firmly established to sloping area

M2

Z WATER RETICULATION (EXCLUDING PILING)

Earthwork

Trenching and backfilling for laving of pipes not exceeding 2.0m depth

Z1 225mm OD HDPE pipe and associated fitting M Z2 110mm OD HDPE pipe and associated fittings M

Install Water Delivery/Distribution Pipelines & Washout Pipelines to Discharge Drain

Z3 Lay & join 225mm OD HDPE pipe with associated fittings M

Z4 Lay & join 110mm OD HDPE pipe with associated fittings M

Supply of Class PN8 HDPE Straight Pipes (inclusive of delivery, store at site)

Z5 225mm OD HDPE pipe M Z6 110mm OD HDPE pipe M

SR-25

Supply of DI Pipes and Fittings (inclusive of delivery, store at site)

Supply of spigot socket DI pipes (Class K9) straight pipes with cement filling

Z7 200mm ND DI pipe M



Supply of double flange DI pipes (Class K9) straight pipes with cement lining




Supply of ductile iron slip-on flange & stub end c/w stainless steel (304) bolts, nuts and washers

Z13 200mm ND stub end with slip on flange NO

Z14 100mm ND stub end with slip on flange NO

Supply of double flange DI Bend (Class K12)

Z15 200mm ND x 90 ̊ NO

Z16 200mm ND x 45 ̊ NO

Z17 100mm ND x 90 ̊ NO

Z18 100mm ND x 45 ̊ NO Supply of DI level invert tee (Class K14)

Z19 200/100mm ND NO Supply of DI tee (Class K14)

Z20 200/200mm ND, all flange NO

SR-26



Z23 150/150mm ND, plain end with flange branch NO


Z25 100/100mm ND, all flange NO Supply of valves, DI Fittings, specials, etc. Sluice valve, double flanged

Z26 200mm ND NO

Z27 100mm ND NO

Z28 80mm ND double air valve with isolating valve NO

Z29 25mm ND single air valve c/w saddle NO DI double flange shortpiece (length=1m)

Z30 200mm ND NO

Z31 100mm ND NO

Z32 150mm ND bulk meter NO

Construction and Installation of Chambers (without piling)

Z33 Chamber for washout NO

Z34 Chamber for air valve NO

Z35 Chamber for sluice valve NO

Z36 Chamber for pillar hydrant NO

Z37 Supply& install respective type of marker posts NO

GENERAL CONDITIONS OF CONTRACT

C-1

THE GENERAL CONDITIONS OF CONTRACT The General Conditions of Contract applicable to this contract is “Swinburne University of Technology Sarawak (SUTS) Form of Contract” which is not provided with the bound set of Tender Document. Tenderers are to obtain copies of the said document at their own cost from Swinburne University of Technology Sarawak (SUTS).

C-2

SWINBURNE UNIVERSITY OF TECHNOLOGY SARAWAK (SUTS)

FORM OF CONTRACT

ADDENDUM TO GENERAL CONDITIONS OF CONTRACT

ADD/C-1


ADDENDUM TO GENERAL CONDITIONS OF CONTRACT

1. Definition Of Terms In this Conditions and in the other documents forming part of the Agreement unless

the context otherwise requires. “Employer” means “Swinburne University of Technology Sarawak (SUTS)”. “Engineer” means BLANC Consultant Firm or any other person for the time being

duly authorized and appointed in writing by the Managing Director of Sarawak Construction (1963) Sdn Bhd as the case may be to act as Engineer for the purpose of the Contract, provided that no person subsequently appointed to be Engineer under the contract shall be entitled to disregard or overrule any decision or approval or directions given or expressed by the Engineer for the time being.

2. IN GENERAL CONDITIONS OF CONTRACT page 8 Clause 30, Determination by

Employer, Sub-Clause 30. “The Director of Public Works ………………………………” should be changed to

“Swinburne University of Technology Sarawak (SUTS) …………………”.

3. IN GENERAL CONDITIONS OF CONTRACT page 12 Clause 37, “Government

stores” should be changed to “Employer’s stores”. 4. IN GENERAL CONDITIONS OF CONTRACT page 7 Clause 26, add the follow sub-

clause:

“26(d) Provided that the Contractor shall have completed the works within the time for completion as provided for in the contract, the Employer shall pay the Contractor a bonus sum calculated at the rate stated in the said appendix as Bonus.”

5. In General Condition of Contract Page 7 Clause 28, add the following paragraph to

end of Sub-Clause 28 (a):

“The employer may exercise his right of Determination by Employer where the Contractor shall make default under Clause 30(a)(iv).”

SPECIFICATIONS

C:\(SuiLan)\20302\Contract_Doc\Spe-Content Page 1 Rev 0

SPECIFICATION CONTENT PAGE SECTION 1 GENERAL AND PRELIMINARIES SP 1.1 - SP 1.10 SECTION 2 SITE CLEARANCE SP 2.1 - SP 2.3 SECTION 3 EARTHWORKS SP 3.1 - SP 3.4 SECTION 4 CONCRETE WORK SP 4.1 - SP 4.18 SECTION 5 TIMBER SP 5.1 - SP 5.2 SECTION 6 PILING SP 6.1 - SP 6.13 SECTION 7 METALWORK SP 7.1 - SP 7.6 SECTION 8 PAVEMENT SP 8.1 - SP 8.13 SECTION 9 FENDER SP 9.1 – SP 9.2

SP 1.1

SECTION 1 - GENERAL AND PRELIMINARIES

TABLE OF CONTENT PAGE NO. 1.1 SCOPE OF WORK SP 1.3 1.2 LUMP SUM CONTRACT SP 1.3 1.3 CONTRACT DRAWINGS SP 1.3 1.5 ENTIRETY OF CONTRACT SP 1.3 1.6 PLANT, TOOLS, VEHICLES, ETC. SP 1.3 1.7 CONVEYANCE OF PLANT AND MATERIALS ONTO SITE SP 1.3 1.8 LIABILITY FOR NUISANCE ETC. SP 1.4 1.9 PRECAUTIONS AND PROTECTIVE WORKS SP 1.4 1.10 SETTING OUT SP 1.4 1.11 PERIOD OF RECTIFICATION AND DEFECTS LIABILITY PERIOD SP 1.4 1.12 REPATRIATION OF LABOUR SP 1.4 1.13 DISCREPANCIES BETWEEN DOCUMENTS SP 1.5 1.14 QUALITY OF MATERIALS SP 1.5 1.15 ASSISTANCE TO ENGINEER’S REPRESENTATIVE SP 1.5 1.16 FACILITIES FOR THE ENGINEER SP 1.5

1.16.1 Site Office SP 1.5 1.16.2 Telephone SP 1.5

1.17 TEST EQUIPMENT SP 1.5 1.18 WATER SUPPLY, SEWERAGE, DRAINAGE AND ELECTRICITY SP 1.6

1.18.1 Scope of the Work SP 1.6 1.18.2 Water Supply SP 1.6 1.18.3 Sewerage and Drainage SP 1.6 1.18.4 Electricity SP 1.6

1.19 TEMPORARY BUILDINGS SP 1.6 1.20 SURETIES SP 1.6 1.21 WAYLEAVES SP 1.6 1.22 TEMPORARY ACCESS SP 1.7 1.23 EXISTING SERVICES SP 1.7 1.24 SOIL CONSERVATION SP 1.7

SP 1.2

1.25 SITE WORKING HOURS SP 1.7 1.26 SITE MANAGEMENT, SITE MEETING, PROGRESS REPORT AND AS-BUILT DRAWINGS SP 1.7

1.26.1 Authorized Site Agent SP 1.7 1.26.2 Site Meeting SP 1.7 1.26.3 As-Built Drawings SP 1.8

1.27 POSSESSION OF SITE SP 1.8 1.28 SAFETY SP 1.8 1.29 PROGRAMME TO BE FURNISHED/PRIORITY OF WORK SP 1.8 1.30 CONTRACTOR’S CAMP AND DUMP SITES SP 1.8 1.31 CLEAN UP SP 1.9 1.32 TIME FOR COMPLETION & DAMAGES FOR NON-COMPLETION SP 1.9 1.33 INSPECTION OF SITE SP 1.9 1.34 SITE PRECAUTIONS SP 1.9 1.35 VARIATION/PAYMENT SP 1.9 1.36 CONTRACTOR TO PROVIDE EVERYTHING SP 1.9 1.37 LOCAL PRODUCTS SP 1.10 1.38 LIMITATION OF SITE SP 1.10 1.39 EXCEPTIONALLY INCLEMENT WEATHER SP 1.10 1.40 CONTINGENCY SUM SP 1.10

SP 1.3

SECTION 1 - GENERAL AND PRELIMINARIES

1.1 SCOPE OF WORK

The contract comprises the design, execution and completion of the works, inclusive of the supply of all materials, labour, plant and equipment, tools and transport & everything necessary for the construction and completion of the RC Jetty Approach and RC Jetty head including piling works and all associated works like bollards, fenders, hand rails etc.

1.2 LUMP SUM CONTRACT

This contract is a lump sum contract. The offer is to be for a lump sum to complete the whole of the works included in the contract.

1.3 CONTRACT DRAWINGS

The drawings forming part of the contract are bound separately and the titles and drawing nos. of these drawings are as listed in the “List Of Drawings”.

1.4 DIMENSIONS AND LEVELS

Written dimensions and levels are to be preferred in every case to scaled dimensions. All scaled dimensions and levels may only be used after confirmation by the Engineer or his accredited representative.

All temporary benchmarks, reference markers and levels as shown on the Drawings shall be checked

on the Site by the Contractor at his own expense and be confirmed by the Engineer. Before the Works or any part thereof are commenced, the Contractor shall verify the levels of the

existing ground surface within areas where earthworks are to be performed and the locations and bed levels of water-courses. These may differ from the locations and levels shown on the Drawings owing to changes which could have taken place during the interval between the original survey and construction.

1.5 ENTIRETY OF CONTRACT

Any matters of construction and workmanship, which are fairly and obviously intended, but may not have been definitely referred to in the Specification or drawings but are usual in sound Construction practice and essential to the works concerned are to be considered as included in the Contract.

1.6 PLANT, TOOLS, VEHICLES, ETC.

The Contractor shall provide everything necessary for the proper and efficient execution of the works together with all requisite plant, tools, implements, lifts, tackle hoists or cranes, mechanical and non-mechanical plant, transport, vehicle, carriage, freightage and all other things necessary for the expeditious execution and completion of the works in proper sequence and for clearing away at completion of earlier as the various items become superfluous and for making good any damage to the finishings or structure and allow for completing any parts of the finishings or structure which may have been temporarily suspended to enable a proper sequence of operations to be maintained.

1.7 CONVEYANCE OF PLANT AND MATERIALS ONTO SITE

The Contractor shall arrange for the conveyance of materials and plant, etc., so as to cause a minimum of damage to existing roads and culverts etc. The Contractor shall be responsible for any damage caused by his lorries or workmen to any existing roads, culverts etc., from whatsoever cause arising and shall maintain, repair and reinstate same to their original condition to the satisfaction of the Engineer or alternatively shall bear the cost of such maintenance and restoration as a deduction from any money due or to become due to the Contractor under this Contract.

SP 1.4

The Contractor shall be responsible at all times for keeping roads immediately adjacent to the site of the

works free from mud, dirt, rubbish, etc., arising out of or in the course of or by reason of the execution of the works and for the observance of any by-law or regulation imposed by the competent authorities requiring roads to keep free from mud, dirt, rubbish, etc.

1.8 LIABILITY FOR NUISANCE ETC.

It shall be clearly and definitely understood by the Contractor that he shall be entirely and wholly taken upon himself all and every risk and responsibility in carrying out the works and be held responsible during the progress of the contract for any damage, accident, annoyances, nuisance or disturbances that may be occasioned to existing premises, residents and users and to the adjoining properties, persons and things by any of the operations arising from the carrying out of this contract.

The Contractor shall be responsible for restricting his workmen only to the site of the new Works, and

shall prevent trepass in to adjoining property and existing buildings in which work is not in progress and he shall undertake properly, substantially, and effectively to reinstate and make good all damages and shall indemnify the Employer against all claims for damages as no responsibility or liability whatsoever shall be undertaken by the Employer in respect of any of the foregoing.

1.9 PRECAUTIONS AND PROTECTIVE WORKS

The Contractor shall comply with all Government regulations, orders, ordinance, instructions or other requirements of any Public Authority having jurisdiction in the matter and shall do all such other things as may be necessary or prudent or as may be otherwise required to ensure the safety and freedom from damage or interference of all of the adjoining or nearby lands, buildings, construction, roadways, footpaths, public or private services and for all other real or personal property of any kind which may at any time be in the vicinity of the site or for the safety and freedom from injury or interference or persons or animals who or which may be at any time in the vicinity of the site and in particular and without affecting the generality of the foregoing shall carry out and provide such shoring, underpinning or other forms of support, shielding, fencing and other precautionary measures as may be necessary for any of the purposes aforesaid, and the obligations of the Contractor under this provision shall be confirming obligations.

1.10 SETTING OUT

The setting out shall be the responsibility of the Contractor and must be carried out by a competent surveyor who shall refer to the Engineer on site to confirm the setting out details. Construction shall not commence until the setting out has been approved by the Engineer on site.

1.11 PERIOD OF RECTIFICATION AND DEFECTS LIABILITY PERIOD

The period of defects liability will be twenty four (24) months commencing from the date that the works receive certificate of practical completion. All works to be rectified will be referred to the contractor in writing from time to time by the Engineer. Not later than 14 days before the expiry of the twenty four (24) months period, the Contractor will be given a detailed list of all outstanding defects to be rectified. The Contractor shall carry out these rectification and hand over the complete works to the Engineer in a satisfactory condition all in accordance with the Conditions of Contract.

1.12 REPATRIATION OF LABOUR

The Contractor shall be responsible for the repatriation of all labour to where recruited and shall maintain such persons being repatriated in a suitable manner until such time as they have left the district. In default the Engineer may maintain and repatriate such persons and recover the cost thereof from the Contractor or may deduct the same from any monies due to or become to the Contractor.

SP 1.5

1.13 DISCREPANCIES BETWEEN DOCUMENTS

The Contractor is to refer to the Engineer, before work is carried out, any discrepancy found in or between the Specifications, Drawings or instructions issued.

Written or figured dimensions on the drawings are in all cases to be preferred to scaled dimensions and

where this has been omitted the Contractor is to refer to the Engineer or his representative.

1.14 QUALITY OF MATERIALS

The whole of the materials and workmanship shall be of the best of their respective kinds, and shall in every case by subject to the approval of the Engineer whose decision in all matters appertaining to quality and suitability of materials and workmanship shall be final and binding.

1.15 ASSISTANCE TO ENGINEER’S REPRESENTATIVE

The Contractor shall render all necessary assistance to the Engineer’s representative and supply all labour, survey instruments and materials required by the Engineer’s representative for carrying out his duties of inspection, supervision, checking and measurement of the Works.

1.16 FACILITIES FOR THE ENGINEER

1.16.1 Site Office The Contractor shall erect, maintain and remove on completion a temporary site office with the following

rooms:- * Engineer’s Office * General Office * Meeting Room * Store * Toilets The offices for the Engineer and his representatives shall be effectively ventilated and lighted and to be

furnished with all furniture, general office equipments including computer and printer and stationeries for the proper running of the office.

The Contractor shall provide workmen to maintain and clean the offices and furniture therein throughout

the active period of the Contract and clear away whole within one week on completion of Contract.

1.16.2 Telephone

The Contractor shall install a telephone for the Engineer’s site office. The Contractor shall pay all charges for registration, installations and running costs for the telephone excluding charges for outstation calls. At the end of the Contract Period, the telephone will be the property of the Contractor.

1.17 TEST EQUIPMENT

The Contractor shall provide and maintain for the period of the Contract the Test Equipment as listed below. The test equipment shall become the property of the Contractor at the end of the Contract. The equipment shall conform to the relevant British Standards.

The Contractor shall employ a competent technician in taking samples and to carry out standard tests. Other laboratory tests shall be carried out by approved well equipped material laboratory.

SP 1.6

List of Testing Equipment

Item Description Nos.

1.

2.

3.

4.

Steel rule - 12” Standard 150 mm concrete test cube steel mould to BS 1881 Slump cones and with tamp rods to BS 1881 Tanks for curing of concrete specimens

1

6

1

1

1.18 WATER SUPPLY, SEWERAGE, DRAINAGE AND ELECTRICITY

1.18.1 Scope of the Work The Contractor shall make arrangement for the provision and maintenance for the various buildings

such as living quarters, site office, Engineer’s office, workshops, stores and for sewerage systems, electricity and water supply.

1.18.2 Water Supply

The Contractor shall make his own arrangement for potable water supply to the approval of the Engineer.

1.18.3 Sewerage and Drainage

Sanitary facilities, piping, sewers, manholes and septic tank serving the Engineer’s office and various buildings shall be provided to the approval of the Engineer.

Drains for the area around these buildings shall be constructed to the satisfaction of the Engineer.

1.18.4 Electricity

The Contractor shall make his own arrangement for the electricity supply to the satisfaction of the Engineer.

1.19 TEMPORARY BUILDINGS

All temporary buildings erected on the site by the Contractor are to be in positions to be approved by the Engineer and the Contractor is to comply with the requirements of local or other authorities and obtain any necessary licenses and pay any fees and charges.

1.20 SURETIES

The Contractor shall provide surety in accordance with Clause 5 of the General Conditions of Contract, amounting to 5 per cent of the Contract Sum.

1.21 WAYLEAVES

The Contractor shall bear all expenses and charges for spedal and temporary wayleaves in connection with access to the site, and provide for the cost of any additional accommodation outside the site required for the purpose of this Contract.

SP 1.7

1.22 TEMPORARY ACCESS

The Contractor shall provide and maintain any necessary temporary roads, sleeper tracks, ramps, temporary cross-overs to and within the site etc., and temporary site drainage as required during the execution of the work, and clear away same at completion, and reinstate and make good any work disturbed all to the satisfaction of the Engineer. The Contractor shall pay all charges and fees in connection therewith.

1.23 EXISTING SERVICES

The Contractor shall make all necessary enquires to ascertain the positions of underground services, including electricity and telephone cables, drains, water supply pipes, etc., and any such information given on drawings or by the engineer is given as a guide only and does not relieve the Contractor of the responsibility of making his own enquires.

1.24 SOIL CONSERVATION

The Contractor shall take all necessary precautions to prevent the erosion of soil and earth slips from slopes. He shall construct adequate temporary water courses, drains and silt traps to prevent any eventuality of an earth slip. The Contractor shall desilt all silted-up drains, blocked pipes and culverts, sumps and repair all failed slopes where they occurred, all to the satisfaction of the Engineer. All costs in connection shall be deemed to be included in the Contract Price.

1.25 SITE WORKING HOURS

The Contractor shall take note that the normal working hours of the Engineer is as follows :- Monday to Friday : 8.30 am to 5.00 pm (with 1 hour break for lunch) Saturdays : 8.30 am to 12.30pm Sunday and public holidays are not working days. If the Contractor’s work required the supervision of

the Resident Engineer and/or any of his staff outside the aforesaid normal working hours then the Contractor shall reimburse all overtime supervision cost incurred by the Employer due to such working outside normal working hours. Payment for overtime supervision cost shall be made monthly officially and properly documented through the Employer and /or the Consultant. Direct payment to the individual personnel is prohibited.

1.26 SITE MANAGEMENT, SITE MEETING, PROGRESS REPORT AND AS-BUILT DRAWINGS

1.26.1 Authorized Site Agent The Contractor shall provide full and adequate site management and supervision during the progress of

the works, and shall keep a competent and authorised site Agent or General Foreman approved by the Engineer on the site. Such agent or general foreman shall give his whole time to the supervision and management of work and must be able to receive and act on behalf of the Contractor, all instructions, directions or orders issued by the Engineer or his representative.

1.26.2 Site Meeting

The Contractor shall allow for his authorized personnels to attend site meeting monthly or at any time deemed necessary by the Engineer. The Contractor shall submit progress report (in four copies) monthly to reach the Engineer at least 3 days before the date of monthly site meeting. The progress reports shall contain not less than 6 post-card size progress photographs each. Each photograph shall be titled and dated.

SP 1.8

1.26.3 As-Built Drawings

Drawings for recording as-built construction details of the Works shall be prepared by the Contractor and shall be certified by the Engineer or his representative. The originals, in good quality transparencies, and two (2) printed copies of all as-built drawings shall be supplied by the Contractor to the Engineer progressively as sections of the Works become completed. All drawings shall be completed within one month after the completion of the respective section.

As-built drawings shall be A1 size (838 mm x 584 mm) unless otherwise approved by the Engineer.

1.27 POSSESSION OF SITE

In giving the Contractor possession of the site it shall not be deemed that he is to have extensive possession but only a limited possession. Such possession will enable him to perform the works comprised in this Contract. The Employer may at any time take possession of any portion of the ground or building for the purpose of carrying on any other work, or for any purpose whatsoever.

1.28 SAFETY

The Contractor shall be responsible for carrying out the whole of the works, provisions and requirements of the contract or seeing to that they are carried out by all concerned in a thoroughly safe and satisfactory manner and in particular shall:-

(a) Strictly conform to the requirements of any by-laws, regulations, order and advises relating to

the safety of persons on or about the site, made by any public authority and Government having jurisdiction in the matter;

(b) Ensure that all tackles, gears, stagings, scaffoldings, ladders, machines, winding arrangements

and other equipment used in connection with the works shall conform to the requirements of any Government regulation in relation thereto and in any case be adequately strong and safe to use. Immediately discontinue any practice or remove any equipment which becomes or is likely to become dangerous or unsafe;

(c) Provide safety helmets and harness for use by the Engineer or his representative and workers; (d) Remove promptly from the works any employee or representative who by his conduct could

create any danger or nuisance to himself or others.

1.29 PROGRAMME TO BE FURNISHED/PRIORITY OF WORK

Immediately after the formation of the Contract, the Contractor shall submit for the approval of the Engineer a programme showing the full order in which he proposed to carry out the Works including the delivery of the materials to the Site. The Contractor shall make every endeavour to comply with the requirements of the Engineer as to the procedure and sequence of the work but this shall not relieve the Contractor from any of his duties or responsibilities under the Contract.

The Engineer reserves the right to require certain section of works to be accorded with priority over the rest.

1.30 CONTRACTOR’S CAMP AND DUMP SITES

The Contractor is responsible for leasing suitable area for his living quarters, site offices, workshops, sheds, stores, stock piles and other facilities.

The Contractor shall provide and maintain throughout the duration of the Contract such offices, living

quarters, workshops, sheds, stores necessary for the execution of the works. The layout of the camp and all structures erected by the Contractor shall be subject to the approval of the Engineer and shall be maintained, altered and adapted as necessary during the Works.

The Contractor shall be responsible for the provision of all services to the site offices, living quarters,

workshops, sheds, stores, etc. and shall pay all costs and charges in connection therewith.

SP 1.9

The Contractor must strictly adhere to the sanitary and other requirements or regulations in force in the area.

The Contractor shall be responsible for the security of his working area and shall erect at his own

expense, perimeter barded wire fence with gates around the area. At the completion of the Works, the area shall be reinstated to its original condition unless otherwise

permitted to remain by the relevant Government Authorities. All materials for these temporary facilities shall remain the property of the Contractor.

1.31 CLEAN UP

On the completion of construction the Contractor shall clean up and leave in a neat and tidy condition the whole works area and any land occupied by him during the carrying out of the contract.

1.32 TIME FOR COMPLETION & DAMAGES FOR NON-COMPLETION

The contractor shall be requested to complete and deliver up the whole of the works according to the schedules stipulated in the Appendix to Form of Tender. These periods shall begin from the date of handing over of site. Should the contractor fail to complete the works within the time or any extended time fixed under Clause 29 of the General Conditions of Contract, the contractor shall pay the Employer liquidated damages at the rates specified in the Appendix to the Form of Tender until the completion of the works in accordance with Clause 28 of the General Conditions of Contract.

1.33 INSPECTION OF SITE

The contractor is advised to inspect and examine the site and its surroundings before submitting his tender, as to the nature of the ground, the quantities and nature of execution and completion of the work, the means of access to the site, the accommodations he may require, and in general shall himself obtain all necessary information as to risk and contingencies which may influence or affect his tender. No claim will be allowed on the ground of lack of knowledge of the site or of the conditions under which the works are to be executed.

1.34 SITE PRECAUTIONS

The contractor is to take all precautions to prevent nuisance of any kind on the site of adjoining properties. The contractor is to carry out the work in such a way as not to cause inconvenience to public and road users.

1.35 VARIATION/PAYMENT

The contract is a Lump Sum Contract. All the works to be done by the contractor are as shown in the Drawings or as specified in this Special Specification. Any works which are not shown in the drawings but which are specified in this Special Specification are to be done by the contractor and not to be treated as Variation. Any works over and above those shown in the Drawings and which are not specified in this Special Specification will be treated as Variation and the rates inserted for similar items in the Schedule of Rates shall be applicable for the evaluation of such extra works.

Extra work shall not be certified for payment unless it has been authorised in writing by Variation Order

signed by the Engineer. All Variation Orders for extra works and omissions shall as far as possible be made under description employed in the Schedule of Rates.

The Schedule of Rates is to be completed by tenderer.

1.36 CONTRACTOR TO PROVIDE EVERYTHING

Except where otherwise described the contractor is to provide all labour and materials, plant, tools, transport, office store, stores and all other things necessary for the execution of works according to the

SP 1.10

true meaning and intent of the Specifications Drawings or instruction whether or not particularly referred to therein.

1.37 LOCAL PRODUCTS

The Contractor, where possible, shall use materials of Malaysian manufacture/origin as listed below for incorporation into the Works provided that they comply with the requirements specified in preference to imported materials and to the exclusion of the same. In the event that these materials have to be imported then the Contractor is required to ascertain the applicable import restriction, current tariffs for customs surtax and dues and to satisfy himself that import licenses where required for each and any materials proposed to be imported will be issued by the Authorities.

Where a proprietary name is shown on the Drawings or mentioned in the Specification for any material

to be supplied under the Contract, an alternative material of equivalent type and performance will be accepted, subject to the approval of the Engineer in writing.

Specifically cement from Cement Manufacturers Sarawak Sdn Bhd. (CMS), steel bars from Steel

Industry (Sarawak) Sdn Bhd (SIS), steel fabric from Setri Sdn Bhd and precast concrete culverts from PPES Sdn Bhd or its subsidiary are preferred.

1.38 LIMITATION OF SITE

The Contractor shall ensure that all his plants, materials, stores, etc. are kept within the site at locations approved by the Engineer during the construction.

Should the Contractor require additional land outside the site for his workyards, stores, offices,

temporary hand roads or any other temporary structures, he shall, on his own, purchase or rent any additional area he may need.

Areas or area to be rendered as part of the site shall be subject to the Engineer’s approval.

1.39 EXCEPTIONALLY INCLEMENT WEATHER

Extension of time for exceptionally inclement weather shall be based on the number of days in which the amount of rainfall recorded for each calendar day is more than 10mm. Such calculation shall be applicable for each calendar day up to the contracted completion date or the date so extended under Clause 29 of the General Conditions of Contract.

Rainfall readings shall preferably be taken from a measuring gauge installed on site but the current rainfall records at the nearest aerodrome or the nearest DID rainfall station may also be used.

The Contractor shall be deemed to have allowed in his tender and in the programming of the Works for

delay related to the weather which is not exceptionally inclement weather by the above definition and no claims additional to the above shall be entertained.

1.40 CONTINGENCY SUM

A sum has been allowed in the Summary of Tender to cater for any contingencies that may arise during the execution of the Works. This amount may be used wholly or in part as the Engineer may direct or may not be used at all.

SP 2.1

SECTION 2 - SITE CLEARANCE

TABLE OF CONTENT

PAGE NO.

2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL SP 2.2 2.1.1 Description SP 2.2 2.1.2 Construction Methods SP 2.2

SP 2.2

SECTION 2 - SITE CLEARANCE

2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL 2.1.1 Description The work shall consist of clearing, grubbing and stripping topsoil in the areas designated hereunder

and/or shown on the drawings and/or directed by the Engineer, and of clearing only in other areas designated hereunder and/or shown on the Drawings and/or directed by the Engineer, all as specified herein and as required by the Engineer. The work shall also include the demolition and disposal of structures in said areas, except where otherwise provided for in the Contract, as specified herein as required by the Engineer.

(a) Clearing

Clearing shall consist of the cutting and/or taking down, removal and disposal of everything above

ground level, including objects overhanging the areas to be cleared such as tree branches, except such trees, vegetation, structures or parts of structures, and other things which are designated in the Contract to remain, or be removed by other, or which the Engineer directs are to be left undisturbed. The material to be cleared shall include but not necessarily be limited to trees, stumps (parts above ground), logs, brush, undergrowth, long grasses, loose vegetable matter and structures (except those structures whose removal or clearance is otherwise provided for in the Contract). Clearing shall also include the leveling of obsolete dikes, terraces, ditches, etc., unless otherwise directed by the Engineer.

(b) Grubbing

Grubbing shall consist of the removal and disposal of surface vegetation, the bases of stumps,

roots, the underground parts of structures, and other obstructions to a depth of at least 0.50 meter below ground level, all to the satisfaction of the Engineer.

(c) Stripping topsoil

Stripping topsoil shall consist of the removal of topsoil to an average depth of at least 100 mm

below ground level, and its stockpiling for use in the Works, and/or its disposal, as directed by the Engineer. Topsoil Stockpiles shall be limited to a height of 1.5 metres.

2.1.2 Construction Methods

(a) Areas to be cleared

Clearing shall be carried out to the extents deemed necessary and approved or directed by the Engineer.

In areas which are to be cleared only, and in which grubbing and stripping topsoil are not required,

the methods of work shall be such as will not unduly damage the surface vegetation and topsoil, and care shall be taken not to disturb the topsoil and the root systems of grasses and other surface vegetation. No topsoil shall be removed from such areas, except as directed by the Engineer, and any topsoil, grasses and other surface vegetation otherwise removed or disturbed shall be replaced and made good at the Contractor’s expense, all to the satisfaction of the Engineer.

All water courses shall be cleared of obstructions and kept open throughout the works to prevent

ponding in or adjacent to the work areas. Earth bunds or moulds formed during clearing by mechanical means shall be levelled off to permit water into existing natural water courses.

(b) Areas to be cleared, grubbed and stripped of topsoil

Except as otherwise shown on the Drawings and/or directed by the Engineer, clearing, grubbing

and stripping topsoil shall be carried out in all areas of roadway excavation and in all areas where embankment is to be constructed.

SP 2.3

Except where further excavation is required, holes and cavities in the ground surface after clearing,

grubbing and stripping topsoil shall be filled with materials similar to the adjacent ground, and such that of the surrounding material, all to the satisfaction of the Engineer. This work shall be considered incidental to the work of clearing, grubbing and stripping topsoil, and shall not be measured for payment.

(c) Topsoil

Topsoil to be stockpiled for the Works shall be sufficiently fertile to promote and support the growth

of vegetation, and shall be taken from such areas where clearing, grubbing and stripping topsoil is required as approved or directed by the Engineer. Topsoil removed during grubbing stripping operations shall be separated from objectionable materials and spread within the borrow areas, or otherwise disposed of, as approved or directed by the Engineer.

(d) Structures

Major structures are those which cannot practicably be cleared by bulldozer and/or hydraulic

excavator, whose demolition requires pneumatic tools, explosives and/or other specialized equipment.

All fences, buildings, structures, and encumbrances of any character except those to be removed

by others or designated to remain, shall be demolished and removed by the Contractor.

Materials designated in the Contract or directed by the Engineer to be salvaged, shall be carefully removed and stored, and shall be the property of the Employer.

(e) Disposal of material

Unwanted material from clearing, grubbing and stripping topsoil (including the demolition of

structures) shall be disposed of as approved or directed by the Engineer.

No burning is allowed at the site.

SP 3.1

SECTION 3 - EARTHWORKS

TABLE OF CONTENT

PAGE NO.

3.1 DEFINITIONS SP 3.2 3.2 EARTHFILL SP 3.2 3.3 SOURCES OF FILL MATERIAL SP 3.2 3.4 PLACEMENT OF FILL MATERIAL SP 3.3 3.5 COMPACTION SP 3.3

3.5.1 Degree of compaction SP 3.3 3.5.2 Field density testing SP 3.3 3.5.3 Moisture control SP 3.3

3.6 SUBGRADE SP 3.4 3.7 SLIP SLIDES AND CAVE-INS SP 3.4 3.8 FILLING OF EXISTING WATER COURSE SP 3.4 3.9 TURFING SP 3.4

SP 3.2

SECTION 3 – EARTHWORKS

3.1 DEFINITIONS

(1) Formation Level

Formation level means the top surface of the subgrade.

(2) Subgrade

Subgrade means the part of the embankment or existing ground in cutting which is immediately below the subbase or lower subbase of the road pavement and shoulders.

(3) Common Excavation

Common excavation shall mean excavation in any materials which are not rock or artificial hard materials.

(4) Unsuitable Materials

Unsuitable materials shall include:-

(i) running silt, peat, logs, stumps, perishable or toxic material, slurry or mud, or,

(ii) any material, (a) consisting of highly organic clay and silt. (b) which is clay having a liquid limit exceeding 80% and/or a plasticity index

exceeding 55%, (c) which is susceptible to spontaneous combustion, (d) which has a loss of weight greater than 2.5% on ignition, (e) containing large amounts of roots, grass and other vegetable matter, and (f) material having a moisture content making it impossible to achieve the

specified dry density.

3.2 EARTHFILL

Suitable soil materials for earthfill shall be free from organic matter and other deleterious substances, and containing no rocks or lumps over 150mm in greatest dimension with not more than 15 percent of the rock or lumps larger than 60mm in greatest dimension.

The material shall be non-cohesive soils, predominantly granular, non-expansive, free from roots, other organic material and trash. Stones having a maximum dimension greater than 25mm shall not be placed in the upper 300mm of the embankment.

3.3 SOURCES OF FILL MATERIAL

At the time of submission of Tender, the Contractor is deemed to have made all the necessary investigation of his proposed sources of fill material which comply with the Specification, including the necessary clearance, permits and licenses to be issued by the relevant authorities with respect to the extraction of the fill material from the proposed sources and its transportation to the fill site, the time required to obtain such clearances, permits and licenses, the nature of the fill material to be dredged or extracted, the necessary soil investigations, examining site conditions, site survey information in assessing the quality and quantity of fill material that can be supplied and all other aspects which may influence the Tender. In the event of any of the proposed sources indicated by the Contractor being discontinued during the Contract period, the Contractor shall at his own cost provide sufficient quantity of fill materials of the quality which meets with the Specification, from other sources to successfully complete the filling works and no payments for downtime, incurred shall be entertained. The Contractor shall allow in his Tender for whatever contingencies he deems necessary to ensure that availability and a continuous and sufficient supply of the fill material which comply with the Specification.

SP 3.3

The Contractor shall pay all necessary fees, taxes or royalties to the appropriate authorities and observe all regulations pertaining to obtaining suitable fill material from approved borrow pits and this shall be deemed included in his tender price.

3.4 PLACEMENT OF FILL MATERIAL

All fill materials shall be deposited in layers. Each layer shall extend over the full width of the fill area and shall be compacted in accordance with the requirements of Sub-Section 1.5. Each compacted layer shall be maintained at all times with a sufficiently even surface in order to drain away the surface water.

3.5 COMPACTION

The B.S. 1377 Compaction Test (4.5kg rammer method) shall be used in determining the moisture versus density relation of soil.

The Contractor shall submit to the Engineer for his approval the proposed method of compaction for each main type of material to be used in the embankment. This shall include the type of compaction plant for each type of material and the number of passes in relation to the loose depth of material to achieve desired compaction. The maximum compacted thickness for fill shall be limited to 300mm unless otherwise approved by the Engineer. The Contractor shall carry out field compaction trials, supplemented by any necessary laboratory investigations, as required by the Engineer. This shall be done by using the procedures proposed by the Contractor for earthworks and shall satisfy the Engineer that all the specified requirements regarding compaction can be achieved. Compaction trials with the main types of material likely to be encountered shall be completed before the works with the corresponding materials will be allowed to commence.

3.5.1 Degree of compaction

The whole of the embankment below the top 300mm of the subgrade shall be compacted to not less than 90% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5kg rammer method).

3.5.2 Field density testing

The Engineer shall carry out field density tests on each layer of compacted sand fill or earth fill using the sand replacement method in accordance with B.S. 1377 or by using other means of testing of comparable accuracy.

If the results of the field tests show that the state of compaction is inadequate, this is held to be due to the failure of the Contractor to comply with the requirements as stated in this Specification. In such a case, the Contractor shall carry out such further work as the Engineer may decide to be necessary to comply with the requirements stipulated in this Specification.

3.5.3 Moisture control

Each layer of sand fill or earth fill shall be processed as necessary to bring its moisture content to a uniform level throughout the material, suitable for compaction. The optimum moisture content as determined by the BS 1377 Compaction Test (4.5kg rammer method) shall be used as a guide in determining the proper moisture content at which each soil type shall be compacted. Water shall be added, or the material aerated and dried to adjust the soil to the proper moisture content to obtain the required density. A satisfactory method and sufficient equipment as approved by the Engineer shall be used for the furnishing and handling of water.

If the natural water content of suitable materials is too high for the proper compaction to be carried out, the Contractor can either bring down the moisture content by aeration or drying or alternatively replace it with suitable materials of compactable moisture range at his own cost.

3.6 SUBGRADE

Material for the top 300mm of subgrade shall have a minimum California Bearing Ratio (CBR) as shown on the Drawings when compacted to 95% of the maximum dry density determined in the BS 1377 Compaction Test (4.5kg rammer method) under 4 days soaked condition.

SP 3.4

Throughout the top 300mm of subgrade, the material shall be compacted to not less than 95% of the maximum dry density determined in the BS 1377 Compaction Test (4.5kg rammer method).

The subgrade shall be finished in a neat and workmanlike manner, and the widths of embankments and cuts shall be everywhere at least those specified or shown on the Drawings on both sides of the centre-line. The top surface of the subgrade shall have the required shape, superelevations, levels and grades and shall be finished everywhere to within + 10mm and minus 30mm of the required level. Should the subgrade surface be damaged by construction traffic, erosion, water logged due to heavy rain, the Contractor shall at his own cost make good such affected areas prior to laying the subbase course.

3.7 SLIP SLIDES AND CAVE-INS

The removal of materials in slips, slides, cave-ins beyond the lines and levels shown on the Drawings and the subsequent replacement will be the responsibility of the Contractor and no additional payment will be made.

3.8 FILLING OF EXISTING WATER COURSE

Existing water courses for which a diversion has been constructed shall be cleared of all vegetable growth and other unwanted matter and disposed of. Where the existing water course forms an area of embankments, it shall be filled and compacted according to Sub-Section 1.5.

3.9 TURFING

Turf shall consist of healthy dense indigenous cow grass (Axonopus Compresus Species Compresus) firmly rooted into 50mm of topsoil and shall be free from Mimose Lallang and any other plants deemed objectionable by the Engineer. The turf should preferably be laid on the day it is cut, and turf which cannot be laid within three days of cutting may, at the discretion of the Engineer, be used as top soil.

The surfaces to be turfed shall be trimmed and thoroughly wetted. The turf shall then be carefully laid as spot turf as shown on the Drawings. Turf laid on slopes steeper than 1 (vertical) and 3 (horizontal) shall be pegged down with bamboo stakes approximately 250mm in length. Approved fertilizer shall be applied after placing of turf at suitable times and at rates of application approved by the Engineer. All turf shall be regularly watered and fertilized to the satisfaction of the Engineer until the vegetation is satisfactorily established. Any dead turf shall be replaced with new turf at the Contractor's own expense.

SP 4.1

SECTION 4 - CONCRETE WORK

TABLE OF CONTENT PAGE NO.

4.1 GENERAL SP 4.2 4.1.2 Records SP 4.2 4.1.3 Standards SP 4.2 4.2 CONCRETE AGGREGATES SP 4.2 4.2.1 General SP 4.2 4.2.2 Coarse Aggregate SP 4.3 4.2.3 Fine Aggregate SP 4.4 4.3. WATER SP 4.4 4.4 CEMENT SP 4.4 4.5 ADMIXTURES SP 4.5 4.6 CURING COMPOUNDS SP 4.5 4.7 EXPANSION JOINTS, WATERSTOPS, JOINTS FILLERS AND SEALERS SP 4.5 4.8 REINFORCING STEEL SP 4.6 4.8.1 Material SP 4.6 4.8.2 Shop Drawings SP 4.6 4.8.3 Storage SP 4.6 4.8.4 Binding Wire SP 4.6 4.8.5 Bending and Fixing of Reinforcement SP 4.6 4.9 FORMWORK AND FALSEWORK SP 4.7 4.9.1 Design SP 4.7 4.9.2 Materials SP 4.7 4.9.3 Workmanship SP 4.7 4.9.4 Removal of Forms SP 4.8 4.9.5 Tolerances and Defects SP 4.8 4.10 CONCRETE PROPORTIONING SP 4.9 4.10.1 Concrete Mix SP 4.9 4.11 CONCRETE CONTROL SP 4.10 4.11.1 Concreting Testing SP 4.10 4.11.2 Extent of Testing SP 4.10 4.12 CONCRETE WORKMANSHIP SP 4.12 4.12.1 Storage of Materials SP 4.12 4.12.2 Concreting Plant SP 4.12 4.12.3 Batching SP 4.12 4.12.4 Mixing and Transport SP 4.13 4.12.5 Workability SP 4.13 4.12.6 Placing and Compacting SP 4.13 4.12.7 Construction Joints SP 4.15 4.12.8 Expansion Joints Fillers, Waterstops and Sealers SP 4.15 4.12.9 Fixing Blocks, Brackets, Built-in-Bolts, Holes, Chases, Etc. SP 4.15 4.12.10 Curing SP 4.16 4.12.11 Repairs and Rejection of Finished Concrete SP 4.16 4.13 READY-MIXED CONCRETE SP 4.16 4.14 PRECAST CONCRETE UNITS SP 4.16

SP 4.2

SECTION 4 - CONCRETE WORK

4.1 GENERAL

4.1.1 Supervision

Concreting operations shall be carried out under the supervision of a qualified and experience engineer

employed by the Contractor. No concreting work shall be carried out except in the presence of the Engineer or his representative.

4.1.2 Records

A complete record shall be kept by the Contractor of all concrete work, covering quality and quantity of concrete and including records of all tests. One copy of all records shall be filed with the Engineer immediately after the works has been carried out or the tests have been completed.

4.1.3 Standards

The provisions of the latest revised editions of the relevant Malaysian Standard Specification, British Standard Specification, British Standard Codes of Practice, and American Society for Testing and Materials Standards shall be deemed to be incorporated in the Specification including the following :-

MS 522 & B.S. 12 Portland cement (Ordinary and rapid-hardening) B.S. 410 Test Sieves MS 30 & B.S. 812 Methods for sampling and testing of mineral aggregate, sand and filters MS 29 & B.S. 1201 Aggregate from natural sources for concrete (including granolithic) B.S. 1305 Batch-type concrete mixers MS 26 & B.S. 1881 Method of testing concrete MS 28 & B.S. 3148 Tests for water for making concrete MS 145 Steel Fabric reinforcement MS 146 & B.S. 4449 Hot rolled steel bars for the reinforcement of concrete B.S. 4466 Bending dimensions and scheduling of bars or the reinforcement of concrete B.S. 8110: Part 1 The structural use of concrete A.S.T.M C309 Specifications for liquid membrane-forming compounds for curing concrete A.S.T.M C494 Specifications for chemical admixtures for concrete Malaysian Standards shall take preference over all Standards.

4.2 CONCRETE AGGREGATES

4.2.1 General

Materials used as aggregates shall be chemically inert, strong, hard, durable, nonporous, and free from adhering coatings, clay lumps, coal or coal residue and organic or other impurities that may cause corrosion of the reinforcement or impair the strength or durability of the concrete. Aggregates shall comply with MS 29 and B.S. 1201 and be tested in accordance with the requirements of MS 30, B.S. 812 and other standards as specified in Table 4.1.

The aggregates shall be taken from an approved source and shall consist of naturally occurring sand,

stone of igneous origin, crushed or uncrushed, or a combination thereof. They shall not contain water soluble sulphur trioxide (S03) in excess of 0.1 per cent. For work above ground level, suitable limestone may also be approved if there is no sulphur content.

Samples of all aggregates and sand shall be delivered to the site for the trial mix tests, in order that the

Engineer may approve the source. If supplies from the approved source subsequently deviate from the approved samples and do not meet test requirements, then the source will be liable to rejection by the Engineer.

SP 4.3

The Engineer may require the Contractor at any time to draw samples of aggregates from stockpiles on the site or any other locations to be indicated by the Engineer for testing by the Engineer according to the methods detailed in MS 30 and B.S. 812. Costs of such samples shall be borne by the Contractor.

Aggregates which from tests prove unsatisfactory shall either be replaced or shall be washed until

further tests prove satisfactory. All costs and expenses incurred to comply with this requirement shall be borne by the Contractor. Rejected aggregates shall be removed from the site.

Sieving and remixing of aggregates whose gradings fall outside the specified limits may be permitted at

the sole discretion of the Engineer and at no extra cost to the Employer. Aggregates shall be stored in bins with clean hard floors. The bin floors shall be constructed so as to

permit free drainage or moisture from the aggregates. Whenever required by the Engineer, aggregates shall be hosed down to restore the specified standard of cleanliness. Aggregates collected from marine deposits shall not be used in pre-stressed or steam-cured concrete.

Table 4.1 – Testing of Aggregates

Properties Test Methods Limits

Grading Elongation Index Flakiness Index Water Absorption Clay, Silt and Dust Organic Impurities Aggregates Crushing Value Soundness Test (Sodium Sulphate) Chloride Content Sulphate Content

M.S. 30 M.S. 30 M.S. 30 M.S. 30 M.S. 30 M.S. 30 M.S. 30

AASHTO Test Method T104

B.S. 812 Part 4 B.S. 1377 Test 9

See 4.2.2 and 4.2.3 Not exceeding 30% Not exceeding 25% Not exceeding 1.5% Not exceeding 2%

Not exceeding 0.4% Not exceeding 20%

Loss not exceeding 12%

Not exceeding 0.06% by weight of chloride ions

Not exceeding 0.4% by weight of S03

4.2.2 Coarse Aggregate

The coarse aggregate shall be approved crushed granite with the maximum size particles not exceeding the nominal size specified.

The grading of the coarse aggregate shall be within the limits given in the following table (Part of Table

(1) of MS 29 and B.S. 410): Percentage by weight passing B.S. Sieve

B.S. 410 Test Sieve Nominal Size of Graded Aggregate

mm 20 mm to 5 mm

100.0 90.0 75.0 63.0 38.1 37.5 20.0 19.0 14.0 10.0 5.0

- - - - -

100 95 - 100

- 25 - 55 30 - 60 0 - 10

SP 4.4

4.2.3 Fine Aggregate

The fine aggregate shall be natural sand or igneous crushed stone sand free from coagulated lumps and salt and shall contain less than five (5) per cent of clay and silt by volume, measured according to field test in MS 30.

The grading of the fine aggregate shall be within the limits of one of the grading zone in the following

table (MS 29). Fine Aggregate Grading

B.S. Sieve Percentage by Weight Passing

Zone 2

Zone 3 Zone 4

10 5

2.36 1.18 0.6 0.3

0.15

mm mm mm mm mm mm mm

100 90 - 100 75 - 100 55 - 90 35 - 59 8 - 30 0 - 10

100 90 - 100 85 - 100 75 - 100 60 - 70 12 - 40 0 – 10

100 95 - 100 95 - 100 90 - 100 80 - 100 15 - 50 0 - 15

* For crushed stone sand, the limit is increased to 20 per cent.

4.3. WATER

The water shall be clean and fresh and free from organic or inorganic matter in solution or suspensions in such amounts that may lessen the strength or durability of the concrete. Only water of approved quality shall be used for concreting, for flushing and wetting of formwork, and for curing. The Contractor shall make adequate arrangements to deliver and store sufficient water at the work for use in mixing and curing the concrete, and for flushing and wetting forms.

The water shall satisfy the requirements of MS 28 and BS 3184.

4.4 CEMENT

The cement used for concrete shall be CMS cement unless otherwise approved by the Engineer, and shall be normal setting ordinary Portland cement complying with MS 522 and B.S. 12. Consignments shall be used in order of delivery. Each consignment shall be identifiable. For each consignment the Contractor shall supply to the Engineer the date of manufacture and, if requested, a copy of Test Certificate from an independent approved testing body.

The age of the cement at the time of delivery to the Site shall not be more than two (2) months, and the

cement shall be used within two (2) months of delivery. The cement shall be transported to the Site in covered vehicles adequately protected against the weather and shall be properly stored a minimum of 150 mm above ground in approved, well-ventilated, weather-proof, and water-proof buildings to prevent damage through moisture, where cement is stored in bulk in site, the quantity stored shall be limited to no more than one week’s requirement unless otherwise approved by the Engineer.

If it is suspected that the cement is damaged, a series of cube tests as described below will be made in

order to ensure that the specified strength, homogeneity, and density of concrete can be obtained. If this strength is not obtained, the cement will be rejected.

The Engineer may, however, without tests being made, order that any bag of cement, a portion of the

contents of which in the opinion of the Engineer has hardened, or which appears to be defective in any other way, be removed from the site forthwith.

Rapid hardening cement may be used only with the written approval of the Engineer.

SP 4.5

4.5 ADMIXTURES

The use of admixtures may be permitted at the request of the Contractor and at the discretion of the Engineer.

Full particulars including specifications and technical data including the source, manufacturer’s name

and trade or brand name shall be submitted to the Engineer for his approval. The chemical names, formulae, and quantities of the active ingredients of the materials, the dosage to

be used and the effects, as well as the effects of progressively less and greater dosages, on the physical and chemical properties of the wet and hardened concrete, shall be submitted to the Engineer for approval.

The Contractor shall provide such samples and carry out such tests, as the Engineer may direct prior to

permitting the use of admixture in the works. All such samples and tests shall be provided at the Contractor’s expense.

The Engineer may at any time require further samples and tests to be carried out after the materials has

been delivered to the Site. The warranted shelf life of the material and the shipping and storage conditions under which it is

applicable shall be stated by the manufacturer, and the Contractor shall comply with these requirements in all respects.

The use of calcium chloride in the concrete will not be permitted. Admixture shall comply with the requirement of A.S.T.M. C494.

4.6 CURING COMPOUNDS

Concreting curing compounds shall be of manufacture approved by the Engineer. All concrete curing compounds shall be non-staining and shall comply with the requirements of A.S.T.M.

C309 where relevant.

4.7 EXPANSION JOINTS, WATERSTOPS, JOINTS FILLERS AND SEALERS

Waterstops at construction joints shall be of manufacture approved by the Engineer suitable for horizontal and vertical construction. P.V.C. type waterstops with hollow central bulb shall only be used for joints not subject to differential shear movement. For joints at high movement areas, rubber waterstops with hollow central bulb shall be used.

Joint fillers shall be insoluble synthetic resin bounded granular cork self-expanding filler of manufacture

approved by the Engineer complying with A.S.T.M. D1752-67 (R73) Type III and American National Standard A 37-144-1969(R75) Type III.

Sealer shall be Heavy Duty Sealer cold applied two part polysulphide pitch extended sealant of

manufacture complying with B.S. 5212 and U.S. Federal Specification SS-S200D. Full particulars including specifications and technical data including the source, manufacturer’s name

and trade or brand name shall be submitted to the Engineer for his approval. The Contractor shall also provide such samples and carry out tests as the Engineer may direct and such

samples and tests shall be provided at the Contractor’s expense. The Engineer may be anytime require further samples and tests to be carried out after the material has

been delivered to the Site.

The warranted shelf life of the materials and the shipping and storage conditions under which the materials shall be applicable shall be stated by the manufacturer and the Contractor shall comply with these requirements in all respects.

SP 4.6

4.8 REINFORCING STEEL

4.8.1 Material

Steel bars for Concrete Reinforcement shall be SIS steel bars and Reinforcing Steel Fabric shall be Setri Fabric. Mild steel reinforcement rod shall be hot rolled mild steel bars of a manufacture approved by the Engineer and shall comply with MS 146 or with a minimum yield of stress of 250 N/mm2.

High yield steel reinforcement rod shall be high tensile bars complying with the requirements of B.S.

4449 with a minimum yield stress of 410 N/mm2. Steel fabric reinforcement shall comply with MS 145. All steel shall be free from oil, dirt, loose rest, scale or other deleterious matter immediately before the

placing of the concrete. Test certificates from an independent approved testing body shall be provided prior to shipment, as

directed by the Engineer. Unless otherwise specified or shown on the Drawings, all steel reinforcement shall be hot rolled,

deformed, high tensile steel bars with yield strength of 410 N/mm2.

4.8.2 Shop Drawings

Shop drawings, bar lists, bending schedules, and installation drawings for all reinforcing steel shall be prepared by the Contractor and submitted to the Engineer for approval prior to fabrication. Detailing shall conform to requirements of B.S. 4466.

The Engineer’s approval does not relieve the Contractor in any way of his responsibility for accuracy

and/or completeness of the detailing work.

4.8.3 Storage

Reinforcing and fabric reinforcing steel shall be stored clear of the ground and in a manner and location which will prevent deterioration. Bars which have become pitted will be rejected, bars which have become dirty shall be cleaned to the satisfaction of the Engineer before being placed in the works.

4.8.4 Binding Wire

Binding wire shall be 16 S.W.G soft annealed typing wire.

4.8.5 Bending and Fixing of Reinforcement

The reinforcement shall be bent in accordance with B.S. 4466 except where otherwise specified. The reinforcement shall be bend cold in manner which will not injure the material. No reinforcement shall be bent when in position in the works, whether or not it is partially embedded in

hardened concrete, unless specially authorized by the Engineer. Reinforcement cages shall be tied into stiff units with intersecting bars tied at least at every second

intersection. The reinforcement shall be kept accurately in position by spacers and chairs secured firmly to the cage.

Bars intended to be in content shall be wired together at all points of contact with binding wire as specified. The types of spacers and chairs used shall be subject to the approval of the Engineer, and any part of a metal spacer or chair shall have at least the same cover as specified for the reinforcement. Mortar blocks shall be of the same strength as the parent concrete. No binding wire may project into the cover concrete.

Bars with loose rust or millscale, or with oil, dirt, grease, mortar or other deleterious matter shall not be

placed in the forms.

SP 4.7

No splices shall be made in the reinforcement except where shown on the Drawings or where approved by the Engineer. The length of splices shall be as specified in B.S. 8110: Part 1 except where otherwise had shown on the Drawings.

Immediately before concreting, the reinforcement shall be examined for accuracy of placing and

cleanliness and corrected if necessary. No concreting shall take place before inspection and approval of the reinforcement by the Engineer.

Reinforcement projecting horizontally at construction joints shall be supported in correct position during

concreting by providing sufficient scaffolding and spacer pieces to which the reinforcement should be tied and held in place.

Bending schedules of the reinforcement bars shall be provided by the Contractor, and shall be made

available for inspection by the Engineer if requested.

4.9 FORMWORK AND FALSEWORK

4.9.1 Design

The Contractor shall submit his designs for approval in ample time before the work commences. The Engineer’s approval of such designs does not relieve the Contractor in any way of his responsibilities for such scaffolding and formwork.

The formwork shall be of sufficient strength to withstand all dead and live loads and the pressure of the

wet concrete and the effects of vibrating without distortion and shall be designed with cambers, etc., necessary to produce the finished structures to the correct levels and profiles. Formwork below high water shall be watertight and shall withstand the effects of tides and waves.

All exposed edges and corners shall be provided with a twelve (12) millimeter chamber unless otherwise

directed.

4.9.2 Materials

All formwork materials, including form oils or other coatings, shall be subject to approval by the Engineer prior to installation and/or application.

Only form clamps of reputable makes and proper steel rod ties with detachable ends shall be used. Wire ties and P.V.C. tubing or other plastic tubing will not be permitted.

4.9.3 Workmanship

The Contractor shall, before erection starts, prove to the Engineer the sufficiency of the forms in accordance with his casting program including type or make of ties or clamps to be used.

All joints in formwork shall be sufficiently close to prevent leakage of grout and the formation of fins or

other blemishes. Openings for inspection of the inside of the formwork and for the removal of water used for washing out shall be formed so that they can be conveniently closed before concreting.

Tie rods specifically manufactured for use as tie rods or other internal spacers as approved shall be

fixed in approved positions so that they can be easily removed, either completely or partly when the shuttering is stripped, and the holes remaining after concreting shall be filled by dry packing and well rammed. No plastic type spacers will be permitted.

No part of any metal tie or spacer remaining permanently embedded in the concrete shall be closer than fifty (50) millimeters to the finished surface of the concrete.

All pipes, bolts, steelwork, and other fixings that are required to be built in or through the concrete shall

firmly fixed in properly aligned position in the formwork, which shall be neatly cut and fitted to suit, joints being caulked where necessary to prevent the escape of grout. Likewise, cores and other devices used for forming openings, holes, pockets, chases, etc., shall be fixed to the formwork prior to the wet concrete reaching their level.

SP 4.8

The inner faces of the formwork shall be formed or treated so as to minimize adherence to the concrete. If form oil or similar coatings are used, they shall be kept from contact with the reinforcement. If no water impregnating is applied to wooden forms, they shall be thoroughly wet before concreting starts.

Before any concreting is commenced, all the formwork shall be blown clean to remove dirt, shavings,

sawdust, and other refuse, and all formwork shall be inspected and approved by the Engineer before any concrete is placed. The compressed air used in cleaning shall be free from any trace of oil film whatsoever, as confirmed in the presence of the Engineer immediately prior to use.

4.9.4 Removal of Forms

No formwork shall be removed without the approval of the Engineer, but the giving of such approval shall in no way relieve the Contractor of any of his contractual responsibilities.

The removal of formwork shall be carried out carefully so as to avoid damaging the concrete. Before

soffit forms and props are removed, the concrete shall be exposed by removal of the side forms or otherwise as required by the Engineer in order to ensure forms may be removed after twenty-four (24) hours provided the concrete is sufficiently strong so as not to be injured and proper arrangements have been made for curing.

Load carrying forms may be removed when those site-cured test specimens which are cured in the

same conditions as the permanent work indicate sufficient strength to carry the induced load at or soon after the time of removal and when the Engineer is satisfied that all the relevant clauses of the Specification have been met. The removal of formwork and falsework shall be executed by gradual easing without jarring and only in the presence of a competent supervisor.

Load carrying concrete will be deemed to have sufficient strength to allow removal of the forms when

each of the corresponding site-cured additional test specimens has attained a crushing strength no less than half the twenty-eight (28) days design strength.

The stripping times given in the following table are the minimum for the several cases, but it is

emphasized that the information given in the table is for the Contractor’s guidance only and the times may be varied to suit abnormal climatic conditions and other special circumstances.

Stripping Times

Sides of Walls, Beams and Columns

Soffits of Slabs (props left in place)

Props to Slabs

Soffits of Beams (props left in place)

Props to Beams

3 days

7 days

14 days

10 days

18 days

The minimum removal times for concrete containing rapid-hardening Portland Cement shall be one-half

of the values tabulated, where such use is approved by the Engineer. No superimposed loading or pressure shall be applied to any part of a structure until permission is given

in the Engineer.

After the removal of the formwork or falsework, the work shall be inspected by the Engineer before any touching up is done.

4.9.5 Tolerances and Defects

The permissible surface tolerances shall not exceed the limits shown on the following table. Notwithstanding the details shall be applied in preference at all times. If required, the Engineer may impose smaller tolerances.

If, in the opinion of the Engineer, the formwork is cut, drilled, bent, buckled, repaired or generally

damaged in a way detrimental to the appearance of the concrete or to the tightness or straightness of the forms, it will be rejected.

SP 4.9

Example of Permissible Tolerances

Condition Final Structure Tolerance

Variation in cross sectional Dimension of structural members Departure from alignment as shown on the Drawings (End to the End) Departure from level of top surfaces as shown on the Drawings (End to End) Departure from level of under side surfaces as shown on the Drawings (End to End) Gradual deviations from the dimensions shown on the Drawings, measured from a template one (1) metre long Offsets or fins caused by defective formwork or otherwise

4mm

12mm

12mm

12mm

3mm

4mm

4.10 CONCRETE PROPORTIONING

4.10.1 Concrete Mix

The concrete mix shall comply with the requirements of the Concrete Mix Table specified hereinafter. The proportions of cements, fine and coarse aggregates, water, and admixtures necessary to produce

concrete conforming to the requirements of the Concrete Mix Table shall be determined by the Contractor in a series of trial mixes on the concrete to be used on the job.

The series of trial mixes shall be made at least five (5) weeks before concrete placing is due to start and

shall be sufficiently comprehensive for concrete proportions to be selected to the satisfaction of the Engineer. Both seven (7) and twenty-eight (28) day strengths of the trial mix, determined as the average of three (3) test specimens, shall exceed the specified strength. The Engineer’s approval of the trial mix including twenty-eight (28) day strength results shall be obtained in writing before any concrete is permitted to be placed in the works. If possible, the concreting plant and the means of transport to be employed in the works shall be used to make the trial mixes and to transport them a representative distance. A clean mixer shall be used and the first batch discarded.

If during the progress of the work, the Contractor desires to use materials or proportions other than

those originally approved, or if the materials from the sources originally approved change in characteristics, he shall provide evidence satisfactory to the Engineer that the new materials and/or combination of materials will produce concrete meeting the requirements herein.

SP 4.10

Concrete Mix Table

1. Grade or Characteristic

Strength 28 days N/mm2

10

20

25

30

35

40

45

2. Min. Works Cube Strength

7 days N/mm2

-

15

18.75

22.50

26.25

30

33.75

3. Max. Coarse Aggregate

Size (mm)

20

20

20

20

20

20

20

4. Min. Cement Content

(kg/m3)

250

325

360

360

360

400

400

5. Max. Cement Content

(kg/m3)

550

550

550

550

550

550

550

6. Max. Water/Cement Ratio

0.65

0.50

0.49

0.45

0.44

0.42

0.41

The mix shall contain not more than five hundred and thirty four (534) kg of cement per cubic metre of

hardened concrete. The Contractor shall carry out the tests on the initial trial mixes as well as such further trial mixes and

corresponding tests as may be required during the execution of the works in order to account for changes in materials or working conditions.

The cost of such test shall be deemed to be included in the cost for concrete work.

4.11 CONCRETE CONTROL

4.11.1 Concreting Testing

Unless otherwise specified below, all concrete control testing shall be carried out by the Contractor with his own equipment under the supervision of the Engineer. For this purpose, the Contractor shall notify the Engineer reasonable in advance when tests are being made, repeated or when extra tests are being made, the Contractor shall make available the testing equipment for the use of the Engineer and make available all records for inspection. Duplicate copies of all test results, analyses, etc., shall be supplied to the Engineer on printed forms approved by him.

4.11.2 Extent of Testing

Minimum requirements regarding tests which shall be carried out in order to control concrete quality are given on the Concrete Control Tests Table below.

The frequency of control tests shall be regulated as experience is gained regarding the fluctuations to

be expected in the properties tested. Unless otherwise decided by the Engineer, all tests shall be carried out in accordance with the relevant

British Standard Specifications. Where no such standard exist standards of the American Society for Testing Materials (A.S.T.M.) shall apply.

Neither the mix proportions nor the sources of supply of materials shall be altered without the prior

approval of the Engineer, except that the Contractor shall adjust the proportions of the mix as required to take account of permitted variations in the materials.

SP 4.11

Concrete Control Tests Table

Test No. Material or Property Frequency Group

1 Daily or per Shift

2 Periodically

1.

1.1

2. 2.1

3.

3.1 3.2

4.

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

5.

5.1 5.2 5.3 5.4 5.5

6.

6.1 6.2 6.3 6.4

7.

7.1 7.2 7.3

Cement Acceptance Test Water Acceptance Tests Admixtures (A.S.T.M. Specification) Retarding Effect Effect on strength Aggregate Organic Impurities Material finer than No. 200 Screen Screen Analysis Impurities, Soft Particles, etc. Specific Gravity Absorption Unit Weight Porous Particles Clay Lumps Particle Shape Moisture Content Fresh Concrete Mixing Time Consistency Workability Unit Weight Air Content Fresh Concrete Strength Rate of Strength Development Unit Weight Strength Variation Batching & Mixing Plant Control of Scales Control of Mixtures Dispensers for Admixtures

X (1) X (1)

X

X

X X

X X X X X X X X X X X

X

X X

X X X X

X X X

(1) Possibly several time a day. Re: Test No. 1 Cement For each consignment of cement delivered, samples shall be taken out for full standard tests both

physical and chemical. Re: Test No. 3 Admixtures Apart from acceptance tests in accordance with the relevant A.S.T.M. Specification, these materials

must be tested in concrete made using the cement and the aggregate which will be used on the job. Re: Test No. 4 Aggregates The moisture content of the fine aggregate will be determined whenever a change is suspected, and at

intervals as determined by the Engineer. Re: Test No. 5 Workability

SP 4.12

The workability of the concrete will be tested at intervals on samples obtained at the place of concreting. Re: Test No. 6 Hardened Concrete Samples of concrete for tests will be taken and cubes made, as determined by the Engineer. Compressive strength will be determined by the Engineer using test cubes 152 x 152 x 152 mm. The

cubes will be compacted by vibration, cured, stored, transported, and tested in accordance with MS 7.1. The strengths will be determined after twenty-eight (28) days as the averaged of three (3) cubes made from the same batch of concrete which will be considered as a test. Normally, four (4) cubes will be made from concrete in a mix selected at random on each day concrete is being placed, or in general for each one hundred and fifteen (115) cubic meters of concrete whichever is the more often. One of the four (4) cubes taken at each sampling will be tested at seven (7) days or at the discretion of the Engineer and the remaining three (3) cubes will form a twenty-eight days test as described above. Additional cubes may in certain cases be tested after seven (7) days.

A record of all tests identifying the test cubes with the part of the work executed will be kept on the Site

by the Engineer and made available to the Contractor on request. If the specified requirements have not been met, the Contractor shall take such remedial action as the

Engineer may order, and shall, before the proceeding with the concreting, submit for the Engineer’s approval, details of the action proposed to ensure that the concrete still to be placed in the works will comply with the Specifications.

To determine the permissible time for removal of load carrying forms, extra test cubes will be cast and

cured under the same conditions as the permanent work. The cubes will be tested in sufficient time before removal of forms for the Engineer to evaluate the result.

The Engineer may require cylindrical core specimens to be cut from the hardened concrete where the

specified cube strength requirements have not been met. The Contractor shall arrange for cores to be cut and the specimens shall be dealt with in accordance with MS 26 and B.S. 1881.

The cutting equipment and method of doing the work shall be approved by the Engineer. Prior to

preparation for testing, the specimens shall be made available to the Engineer. If the compressive strength of any core specimen is less than the twenty-eight (28) days characteristic

strength as described in the Concrete Mix Table, or if, in the opinion of the Engineer, the concrete fails to meet the specified requirements in other respects, the concrete in that part of the works in which it is a sample will be considered not to comply with the specified requirements and shall be replaced if so directed by the Engineer, all at the Contractor’s expense.

4.12 CONCRETE WORKMANSHIP

4.12.1 Storage of Materials

Cement, aggregates, or admixtures shall be stored on the Site in such a manner as to prevent deterioration or contamination by foreign matter. Any material which, in the opinion of the Engineer, has deteriorated or has been contaminated or otherwise damaged shall not be used for concrete and shall forthwith be removed from the Site at the Contractor’s expense.

4.12.2 Concreting Plant

Any concreting plant erected by the Contractor shall be suitable in type, capacity, and design for its purpose. The performance of the plant and its disposition shall be to the satisfaction of the Engineer.

Concreting plant as referred to herein include any aggregate or cement handling and storage plant, batching and mixing plant, transporting, depositing and vibrating plant.

4.12.3 Batching

Materials for designs mix concrete shall be weight-batched. Aggregate may be weighed cumulatively, but cement shall then be weighed on a separate scale.

SP 4.13

Water shall be measured by weight or by volume. Allowance shall be made throughout for the moisture content of the aggregates by approved means. Admixtures, if permitted, shall be measured using suitable dispensers, and shall be used strictly in accordance with the manufacturer’s instructions.

Weight-batches shall be calibrated frequency and whenever so required by the Engineer. After each concreting, the Contractor should check that the cement content is as specified above by

comparing the volume of concrete cast against the number of bags of cement used.

4.12.4 Mixing and Transport

All concrete shall be mixed mechanically, Mixing time, drum speed, and other details shall be approved by the Engineer.

The mixing, unless otherwise approved, shall be carried out in an approved mechanical batch mixer of

adequate capacity and complying with B.S. 1305 “Batch Type Concrete Mixer”. The mixer shall be equipped with an automatic water measuring tank fitted with a device for locking the discharge setting. Mixing shall continue until there is a uniform distribution of materials and the mass is uniform in colour and consistency. The minimum mixing time after all materials are placed in mixer is to be two minutes.

Mixer drums shall be empty before recharging and shall be washed out and cleaned at the end of each

working period. They shall at all times be kept free from hardened concrete and shall be primed by an approved grout wash when mixing is resume.

The concrete shall be discharged from the mixer and transported to the works by means that shall be

approved by the Engineer and which shall prevent segregation or loss of ingredients, and ensure that the concrete is of the required workability at the point and time of placing. Concrete buckets shall be of a type with controllable gates, which permit both partial and complete emptying. Where concrete is to be transported some distance, precautions shall be taken to protect it from direct sunlight, rain, drying winds or dust.

Transporting plant shall be of a design enabling the concrete to be dumped vertically over the required

point of placement. The plant shall be kept free from hardened concrete and shall be rinsed down prior to use. All free flowing water shall be removed.

Dumping at an angle or the working of the concrete by vibrators or otherwise to make it flow laterally

shall not be permitted.

4.12.5 Workability

The concrete shall be of such consistency that it can be readily worked into the corners and angles of the formwork and around reinforcement without segregation of the materials or bleeding of free water at the surface. On striking the formwork it shall present a face, which is uniform, free from honey-combing, surface crazing, or subsequent excessive dusting, and which shall not, in the opinion of the Engineer, be inferior to the standard referred to below.

In order to satisfy the Engineer that the workability of the proposed mix is adequate for the requirements

of the Specification, the Contractor shall carry out a series of workability tests on the preliminary trial mixes. These tests shall be carried out in accordance with MS 7.1, or such other procedure as may be approved by the Engineer. The samples to be tested shall be obtained from the batches used for the preliminary test cubes.

4.12.6 Placing and Compacting

The Contractor shall have the necessary equipment for mixing, transporting, placing, and compacting on Site before placing is started in order to finish without unplanned construction joints. The concrete shall be placed in the positions and sequences indicated on the Drawings, in the Specification, or as directed by the Engineer.

Concrete shall not be placed unless the Engineer has previously examined and approved in writing the

positioning, fixing and condition of the reinforcement, and of any other items to the embedded, and the cleanliness, alignment, and suitability of the containing surfaces.

The concrete placing shall be deposited as nearly as possible in its final position, it shall be placed in

such a manner as to avoid segregation of the concrete and displacement of the reinforcement, other

SP 4.14

embedded items, or formwork. It shall be bought up in horizontal layers not exceeding four hundred (400) millimeters in compacted thickness unless otherwise authorize or directed by the Engineer. Placing shall be continuous between specified or approved construction joints without undue interruptions including lunch periods.

Where chutes are used to convey the concrete, their slopes shall be such as not to cause segregation,

and suitable spouts sor baffles shall be provided to obviate segregation during discharge. Concrete shall not be allowed to fall freely more than one (1) metre.

Where pneumatic placers are used, the velocity of discharge shall be regulated by suitable baffles or

hoppers where necessary, to prevent segregation or damage and distortion of the reinforcement, other embedded items and formwork, caused by impact.

The concrete shall be placed in its final position in the forms before loss of workability occurs, and in no

case later than forty-five (45) minutes after the mixing water has been added. Adding water after mixing (tempering) will not be permitted.

Concreting shall not take place if rain will cause damage to the concrete. Fresh concrete shall not be placed against insitu concrete which has been in position for more than 45

minutes (or any other period of time as approved by the Engineer if admixture is used) unless a construction joint is formed in accordance with Sub-Section 4.12.7. When insitu concrete has been in place for four (4) hours, no further concrete shall be place against it for a further twenty (20) hours.

No concrete shall be placed in flowing water. Underwater concrete if deemed unavoidable by the

Engineer shall be placed in position by tremies or pipelines from the mixer. Concrete to be placed under water shall be an approved mix with the amount of cement increased by 20%. During and after concreting under water, pumping or dewatering operations in the immediate vicinity shall be suspended until the Engineer permits them to continue. Where the concrete is placed by a tremie, the following requirements shall be applicable:-

i) unless otherwise agreed by the Engineer, when concreting of bored piles is being carried out

under water, temporary casing shall be installed to the full depth of the borehole so that fragments of ground cannot drop from the sides of the hole into the concrete as it is placed;

ii) the hopper and tremie pipe shall be a closed system. The bottom of the tremie shall be kept

as far as practicable beneath the surface of the placed concrete; iii) the tremie pipe shall be large enough with due regard to the size of aggregate. For 20 mm

aggregate the tremie pipe shall be of diameter not less than 150 mm and for larger aggregate, larger diameter tremie pipe shall be required;

iv) unless otherwise agreed by the Engineer, the first charge of concrete shall be placed with a

sliding plug pushed down the tube ahead of it to prevent mixing of concrete and water; v) the tremie pipe shall always penetrate well into the concrete with an adequate margin of safety

against accidental withdrawal if the pipe is surged to discharged the concrete; vi) the concrete shall be deposited wholly by tremie and the method of deposition shall not be

changed part way up to prevent the laitance from being entrapped within the structure; vii) all tremie pipes shall be scrupulously cleaned after use. During hot weather, additional precautions shall be taken to prevent premature setting and lose of water

during placing of concrete in the formwork. These precautions shall include: i) no concrete having an internal temperature exceeding 33 degrees C shall be deposited; ii) concrete shall not be placed in formwork or around reinforcement whose temperature exceeds

36 degrees C; iii) newly placed concrete shall be protected from direct sunlight and from loss of moisture by

covering, shading or other means; iv) no concrete shall be placed when the air temperature at the point of deposition exceeds 36

degrees C.

SP 4.15

All concrete shall be compacted by means of power driven, immersion type vibrators of approved type and performance. The vibrators shall be of a number, size, and capacity to suit the rate of placing, dimensions of concrete, and reinforcement. The concrete shall be fully compacted throughout the full extent of each horizontal layer. It shall be thoroughly worked against the formwork and around any reinforcement and other embedded items without displacing them. Successive layers of the same lift shall be thoroughly worked. Proper vibration techniques shall be employed as directed.

Over-vibration causing segregation, surface laitance, or leaking through formwork shall be avoided.

Immersion vibrators shall be withdrawn slowly to prevent the formation of voids. Vibrators shall not be used in such a way as to damage formwork or other embedded items. The formation of air bubbles against vertical or slopping formwork shall be prevented as far as is practicable with proper placement techniques and tapping of the form in the immediate work area.

All horizontal top surfaces shall be screeded off of screeds as approved to produce an even surface to

the correct level. Surplus concrete shall be removed immediately after consolidation by striking off with sawing motion of a straight edge or template. When some stiffening has taken place in the surface concrete and the moisture film has disappeared, the surface shall receive a foated finished with a uniform texture and free of screed marks.

The horizontal top surface of all concrete walkways shall be finished by brooming to produce a lightly

brush-marked surface to the satisfaction of the Engineer.

4.12.7 Construction Joints

Concreting shall be carried out continuously up to construction joints, the position and arrangement of which shall be as indicated on the Drawings or as approved or instructed by the Engineer. Reinforcement shall be continuous through such joints.

When directed by the Engineer, suitable keys shall be formed on vertical and horizontal joints. Should a construction joint become necessary other than shown on the Drawings, owing to plant

breakdown or other unforeseen reasons, a bulk-head at right angles to the principal lines of stress shall be provided. If, however, the location is near a support or at other location considered undesirable by the Engineer, then the concrete shall be broken back until a suitable location has been reached.

When work has to be resumed on a surface which has set, the whole surface shall be thoroughly

roughened. It shall be cleaned of all loose and foreign matter and laitance, washed with water and all free water removed before placing the fresh concrete which shall be well compacted against the joint. Immediately prior to placing fresh concrete, the contact surface shall be coated with a cement slurry of one part water and three parts cements.

Placing of concrete over horizontal construction joints shall be started by placing on the joint surface a

layer of the specified concrete from which half the amount of coarse aggregates has been omitted.

4.12.8 Expansion Joints Fillers, Waterstops and Sealers

Joint fillers and waterstops shall be used in strict accordance with the manufacturer’s instructions as appropriate to the joint location and where shown on the Drawings.

4.12.9 Fixing Blocks, Brackets, Built-in-Bolts, Holes, Chases, Etc.

All fixing blocks, brackets, built-in-bolts, holes, chases, etc. shall be accurately set out and formed and carefully sealed prior to the concrete being placed. No cutting away of concrete for any of these items shall be done without the permission of the Engineer.

Bolts and other inserts to be cast into the concrete shall be securely fixed to the formwork in such a way

that they are not displaced during the concreting operations, and that there is no loss of materials from the wet concrete through holes in the formwork.

Unless shown otherwise on the Drawings or instructed by the Engineer, reinforcement shall be locally

moved so that the minimum specified cover is maintained at the locations of inserts, holes, chases, etc. Temporary plugs shall be removed and the threads of built-in bolts shall be proved to be free and shall

be greased before handing over any part of the Works.

SP 4.16

4.12.10 Curing

Concrete shall be protected during the first stage of hardening from the harmful effects of direct sunshine, drying winds, rain, or running water. The protection shall be applied as soon as practicable after completion of casting. The concrete shall be covered with a layer of sacking, canvas, straw mats, or similar absorbent material, or a layer of sand, kept constantly wet for ten (10) days in the case of ordinary Portland Cement concrete, or seven (7) days in the case of rapid hardening cement concrete.

The cost of the curing shall be deemed to be included in the Contract Sum. Curing water shall be of a quality similar to the mixing water and shall not stain the concrete exposed to

view.

4.12.11 Repairs and Rejection of Finished Concrete

All finished concrete surfaces shall be true to the required profiles and finished, dense, smooth and free from air holes, honey-combing, and other faults.

After the removal of the formwork, the work shall be inspected by the Engineer before any touching up is

done. Minor blemishes such as small fins, etc., any then be dealt with by stoning or bagging and small air holes stopped with mortar, all as approved by the Engineer.

Any work out of true or with honey-combing or other faults shall be cut back to the extent ordered by the

Engineer and made good with new concrete where larger amounts are involved or in the case of small amounts, with fine concrete epoxy mortar or grout, as approved by the Engineer.

Where, after proof testing, members or structures are not accepted, the Contractor shall either carry out

strengthening, or cut out and replace the defective material, as the Engineer may order. If seven (7) day tests indicate concrete might fail, the Engineer may stop the work on this section until the twenty-eight (28) day results are known and may direct special curing procedures.

Any cost arising out of remedial measures as described in this clause shall be borne by the Contractor.

4.13 READY-MIXED CONCRETE

Ready-mixed concrete shall comply with the requirements of M.S. 523. The concrete shall be carried in purpose-made agitators operating continuously or truck mixers. The concrete shall be compacted and in its final position within 2 hours of the introduction of cement to aggregate and within 45 minutes (or any other period of time as approved by the Engineer if admixture is used) after the addition of water to the cement-aggregate mix unless otherwise agreed by the Engineer. The time of such introduction shall be recorded on the Delivery Note together with the weight of the constituents of each mix.

When truck-mixed concrete is used, water shall be added under supervision either at the Site or at the

central batching plant as agreed by the Engineer, but in no circumstances shall water be added in transit.

Unless otherwise specified, truck mixer units and their mixing and discharging performances shall

comply with B.S. 4251. Ready-mix concrete delivered to the job site shall be accompanied by manufacturer’s certificate stating

the details of mix proportions by weight, grade of concrete, type and size of aggregate, date and time of production, type and dosage of chemical admixtures and other relevant production details in suitable format. In addition the manufacturer shall supply to the Engineer test certificates for testing of materials, indicating the sources of supplies and other relevant details.

4.14 PRECAST CONCRETE UNITS

All precast concrete shall be of the Grade as specified. If any of the precast concrete units are manufactured away from the site of the work, the Contractor shall satisfy the Engineer that the concrete proportions reinforcement, etc., are in accordance with the Drawings and this Specification, and if required, he shall produce samples for testing. Should the Engineer wish to visit the workshop to determine the standard of workmanship or make any progress payment the Contractor shall make way and take such precautionary measures for their safety.

SP 4.17

All precast units shall be handled and stacked so as to avoid damage and ensure that no undue stress

is imposed on them. The Contractor shall remove from the Site and replace at his own costs any precast units which is damaged due to his own negligence or which are rejected by the Engineer.

SP 5.1

SECTION 5 - TIMBER

TABLE OF CONTENT

PAGE NO.

5.1 TIMBER QUALITY SP 5.2

5.2 DEFECTS SP 5.2

5.3 SEASONING SP 5.2

5.4 DIMENSIONS SP 5.2

5.5 SCREWS AND BOLTS SP 5.2

5.6 TIMBERS TO BE CONTINUOUS SP 5.2

5.7 NOTCHING, HOLES, ETC. SP 5.2

SP 5.2

SECTION 5 – TIMBER

5.1 TIMBER QUALITY

All timber shall be of best quality, sound, straight, well seasoned, free from sap shakes, loose knots, radial cracking or other imperfections.

All timber shall be stored in approved locations and an acceptance moisture content be maintained in

the timber, before incorporation in the Works.

5.2 DEFECTS

All timbers is to be sawn square with the slope of the grain not exceeding one in eight, and is to be free from sapwood, twists, splits, cracks, large, loose or dead knots, large resin pockets, waney edges, live or extensive insect attack or other defects except to such extent as may be permitted by the Engineer where the strength, durability or appearance of the work will not be affected.

5.3 SEASONING

Timber for structural purposes is to be adequately seasoned before use so as to prevent undue shrinkage, distortion or splitting, and any timber which subsequently develops before the end of the Defects Liability Period such defects so as, in the opinion of the Engineer, to affect unduly the strength, durability or appearance of the Works is to be replaced at the Contractor’s own expense.

5.4 DIMENSIONS

All sawn timbers are to be of the full dimensions specified or shown on the drawings. For wrot timbers, unless finished sizes are specified, 2.5 mm will be allowed off the stated sizes for each wrot face.

5.5 SCREWS AND BOLTS

All nails, screws, bolts and other fastenings are to be of a suitable type and size and in sufficient number.

Where necessary to avoid splitting, holes for nails are to be pre-bored of diameter not exceeding four-

fifths that of the nail. Holes for bolts are to be bored from both surfaces of the timber, and are to be of a diameter equal to 11/16 times that of the bolt. Washers are to be used under all nuts and bolt heads. Nuts are to be brought up tight but not so as to crush the timber.

5.6 TIMBERS TO BE CONTINUOUS

Every post, beam, tie and similar member is to extend in one piece between its supports or fixings unless otherwise specified or approved in writing, in which case it is to be adequately jointed in an approved manner.

5.7 NOTCHING, HOLES, ETC.

Where joists, rafters, etc., are notched over supports the depth of the notch is not to exceed two-fifths of the depth of the member.

Holes in joists, etc., for pipes are to be as near to the neutral axis as possible and are not to exceed

one-quarter of the depth of the member.

SP 6.1

SECTION 6 - PILING

TABLE OF CONTENT

PAGE NO. 6.1 GENERAL SP 6.3 6.2 WELDING SP 6.3 6.3 EQUIPMENT SP 6.3 6.3.1 Pile Cushion Block SP 6.4 6.3.2 Templates SP 6.4 6.4 PILE DRIVING SP 6.4 6.4.1 Piles Out of Alignment or Position SP 6.4 6.5 PILE RECORDS SP 6.4 6.6 TEST PILES SP 6.5 6.7 PILE LOAD TESTS SP 6.5 6.7.1 Pile Load Tests SP 6.5 6.7.2 Constant Rate of Penetration Tests SP 6.5 6.7.3 Maintained Load Test SP 6.5 6.8 TENSION TEST PILE SP 6.6 6.9 DEFECTIVE PILES SP 6.6 6.10 RISEN PILES SP 6.6 6.11 CUTTING OFF AND CAPPING PILES SP 6.6 6.12 PRESTRESSED SPUN CONCRETE PILES SP 6.7 6.12.1 Description SP 6.7 6.12.2 Materials SP 6.7 6.12.3 Casting SP 6.7 6.12.4 Handling and Storage SP 6.7 6.12.5 Pitching of Piles SP 6.8 6.12.6 Driving of Piles SP 6.8 6.12.7 Lengthening of Piles SP 6.8 6.12.8 Cutting and Preparation of Pile Heads SP 6.8 6.13 STEEL PIPE PILES SP 6.8 6.13.1 Description SP 6.8 6.13.2 Materials SP 6.8 6.13.3 Manufacture And Storage Of Steel Pipe Piles SP 6.8 6.13.4 Workmanship SP 6.9 6.13.5 Installation Of Steel Pipe Piles SP 6.10 6.14 PROTECTIVE TREATMENT FOR STEEL PIPE PILES SP 6.10 6.14.1 General SP 6.10 6.14.2 Standard Specification SP 6.10 6.14.3 Documents Required SP 6.10 6.14.4 Manufacturer’s Standard Coatings SP 6.11 6.14.5 Personnel SP 6.11 6.14.6 Paint Delivery SP 6.11 6.14.7 Paint Storage SP 6.11 6.14.8 Application of Paint SP 6.11 6.14.9 Handling and Storage of Painted Steelwork SP 6.12

SP 6.2

6.14.10 Surface Preparation SP 6.12 6.14.11 Repairs to Damaged Surfaces SP 6.12 6.14.12 Inspection SP 6.12 6.14.13 Equipment and materials SP 6.13 6.14.14 Protective Treatment SP 6.13

SP 6.3

SECTION 6 – PILING

6.1 GENERAL

a) Piling shall conform in all respects with the principle contained in BS 8004. b) In addition to submitting the records required under Clause 5.5.1 the Contractor shall report

immediately to the Engineer any circumstances which indicates that the ground conditions differ from those expected by the Contractor from his interpretation of the Soil Survey so as to affect materially the bearing capacity of the pile.

c) Piling shall be a provisional sum item. Remeasurement shall be carried out using the rates

entered in the Summary of Tender. All steel piles must be fabricated in accordance to the details shown in the drawings. d) The Engineer may select for testing one or more working piles which the Contractor shall

construct or drive in advance of the remaining piles at the Site. Piles selected for this purpose shall be constructed or driven with the same equipment as proposed for the main piling work, to the depths required by the Engineer. The remaining piling at the site shall not proceed until the testing of the advance piles has been completed to the satisfaction of the Engineer, and meets the requirements of acceptance quoted in Clause 5.6. The Engineer may also instruct the testing of further piles during the course of the works. All pile testing shall be carried out in accordance with Clause 5.6 and 5.7.

6.2 WELDING

a) All welding shall be carried out in accordance with the requirements of B.S. 5135 - Metal-Arc Welding of carbon and carbon-manganese Steel.

b) The Contractor shall supply the Engineer with full details of his proposed method of welding

and shall, if required, arrange for a demonstration. c) Only competent welders shall be employed on the Works.

6.3 EQUIPMENT

a) The Contractor shall provide and maintain in first class operating condition all equipment necessary for the proper and efficient handling and installation of piles.

b) Pile driving leads, templates and hammer extensions employed in the driving of piles shall

assure continual control of the alignment between pile hammer and pile throughout the entire driving cycle. Equipment utilized to guide the piles shall be designed and employed so as to minimize bending movements in pile during setting and driving.

c) The hammer shall be equipped with a capblock, of known and permanent elastic

characteristics, approved by the Engineer. d) Driving heads or followers shall cover the entire head of the pile, maintaining concentricity

between the hammer and pile, efficiently transmitting below energy from hammer to pile, and enclosing a wood cushion block required to protect the pile head during driving.

e) Piles shall be supported in line and position with leads while being driven. Pile driver leads

shall be constructed in such a manner as to afford freedom of movement of the hammer, and they shall be held in position by guys or steel braces to insure rigid lateral support to the pile during driving. The driving of piling with followers shall be avoided if practicable and shall be done only under written permission from the Engineer.

SP 6.4

f) The pile driving equipment used in driving the foundation piles shall be the same as those used in driving the test piles from which the driving procedure has been established.

6.3.1 Pile Cushion Block

a) The heads of all steel piles shall be protected with a soft wood cushion block of sufficient thickness to effectively and uniformly distribute hammer blow energy. The cushion block shall be inspected periodically during driving and no driving shall be done with a block that has been unduly worn and compressed with use. Cushion blocks must be replaced when compressed to 1/2 of their original thickness, when badly worn or when burning.

6.3.2 Templates

a) Where required by the Contractor or ordered by the Engineer, piles shall be driven with templates to insure proper location, plumpness or batter of the piles; details of the driving templates including full drawings shall be prepared by the Contractor and submitted to the Engineer for approval prior to use. The Contractor shall be responsible for the accurate location and securing of the templates in their correct final positions before driving the piles. All equipment shall be of the type suitable for the proper execution of the Works and approved by the Engineer.

6.4 PILE DRIVING

a) The piles shall be driven to the driving resistance or tip elevation as determined by the Engineer. The minimum depth of pile embedment shall be as directed by the Engineer. The piles shall be driven at the location and to the batters shown of the Drawings.

b) All piles shall be driven within an allowed tolerance of 13 mm per metre of pile length from the

vertical or batter shown on the Drawings. The maximum allowable variation at the butt end of the pile shall be 75 mm in any direction from the location shown on the Drawings or as directed by the Engineer. Any variation beyond these limits shall be allowed or rejected at the sole discretion of the Engineer.

c) Forcible corrections to concrete piles shall not be permitted. Forcible corrections may be

permitted to other types of piles only if approved by the Engineer.

6.4.1 Piles Out of Alignment or Position

The Contractor shall, if ordered by the Engineer, extract and reinstall any pile which has deviated out of position or alignment by more than the specified limit, or alternatively the substructure shall be modified to the approval of the Engineer. The cost of such extraction and reinstallation or any extra cost in the design and construction of a modified foundation shall be borne by the Contractor if, in the opinion of the Engineer, such extra works have been made necessary due to the error and/or negligence of the Contractor.

6.5 PILE RECORDS

a) The Contractor shall keep pile driving or sinking logs for every pile, in a form to be approved by the Engineer, recording in detail all the information required by the Engineer.

b) Duplicate copies of each and every such log shall be furnished to the Engineer within 24 hours

of the completion of the pile in question. c) Upon completion of the piling in each site, the Contractor shall furnish to the Engineer three

copies of an as built drawing recording the precise position, angle of batter, and final tip elevation of all piles and such other information as directed by the Engineer.

SP 6.5

d) The Contractor shall maintain a record of the driving of all piles and shall furnish to the Engineer copies of these records along with any other data required by the Engineer. Immediately after a pile has been driven a record shall be made of the reduced level of the pile head. After the driving of adjacent piles, should any pile heave upwards, it shall be redriven to its original level or, if necessary until its specific set is obtained again.

6.6 TEST PILES

a) In order to determine the required length of pile at each location, the Contractor shall drive test piles as shown on the Drawings and/or ordered by the Engineer. Test piles shall be driven to approximate bearing value as the Engineer may request. Test piles shall be driven with the same hammer that is used for driving foundation piles.

6.7 PILE LOAD TESTS

6.7.1 Pile Load Tests

Pile load tests are carried out before the Engineer issues to the Contractor in writing, instructions on the pile length. The Contractor shall not proceed to supply the piles until he has received instructions in writing to do so from the Engineer.

6.7.2 Constant Rate of Penetration Tests

Each pile load test shall be proceeded by three cycles of pile loading test at a constant rate of penetration carried out in accordance to BS 8004 to a full test load equal to twice the design load. At least twelve reading so settlements and their corresponding loads shall be made in the loading process. After attaining a test load equal to twice the design load, the load is gradually released and at least four readings of settlements and their corresponding loads shall be made during the unloading process. The settlement, when the load is completely released, should also be recorded. An interval of at least 15 minutes must elapse before the next CRP test is commenced.

6.7.3 Maintained Load Test

The three CRP tests are then followed by a Maintained Load Test as follows: - The full test load on a pile shall be twice the design load noted on the Drawings and it shall be applied in

8 equal increments. At least two hours shall elapse between the addition of each load increment. The rate of settlement shall not exceed 0.1 mm in 20 minutes. The full test load shall be maintained on the pile for at least 24 hours and settlements shall be recorded at intervals of not more than 2 hours. The test pile shall then be unloaded in four equal increments at one hour intervals until the full test load is removed.

Settlement readings will be made immediately after and before every load increment is applied or

removed. Settlements shall be measured by use of a reference beam or wire supported independently of the load

test pile, reaction piles or piles supporting reaction loads. Settlements shall be measured to the nearest 0.1 mm for reference beams or 0.5 mm for reference wire. The reference beam support shall be located at least 2 metres from the load test pile, reaction piles or piles supporting reaction loads. The reference beam or wire shall be protected from the effects of temperature changes.

Prior to the performance of any load test, the Contractor shall submit to the Engineer for his approval,

working drawings showing the method and equipment he proposes to use in the performance of the load test and the measuring of settlements; such submission shall include design calculations, lateral supports or other methods used in ensuring against buckling. Horizontal supports to ensure buckling stability shall be provided to the pile to be loaded whenever the ratio of the unsupported height to the least cross-section dimension is 20 or more. Horizontal supports shall provide full support without restraining the vertical movement of the pile in any way.

SP 6.6

Should the pile load test fail, the test pile (or a new pile) shall be driven to a greater depth and a new load test run.

The Contractor shall, within 24 hours of the completion of the test, submit to the Engineer for each pile

test graphs showing:- i) Load and settlement plotted above and below a common base line of time. ii) Settlement and recovery plotted vertically against a base line of load.

6.8 TENSION TEST PILE

The test set up shall consist of a suitable load transferring member from the test pile to the reaction. The suitable load transferring member may be in the form of strands or re-bar. The reaction may be

obtained from the surrounding ground with the help of steel girders and steel mats or from reaction piles. Where reaction piles are used, these shall be spaced not less than 3.2 m away from the pile being load tested.

The movement of the test pile during testing shall be measured using dial gauges which can read to

accuracy of 0.0254 mm. These dial gauges shall be mounted on an independent frame where the support must be at least 2 m metres from the pile or reaction.

The load procedure to be adopted shall be the Maintained Load Method. Loading shall be carried out in increment of 25% of working load (W.L.) and each increment shall be

maintained for at least 1 hr. At W.L. the load shall be maintained for at least 24 hours. At the maximum test load of 1.5 W.L., the load shall be maintained for at least 24 hours. Unloading shall be carried out in four approximately equal increments and each increment shall be maintained for at least 1 hour.

6.9 DEFECTIVE PILES

The method used in driving piles shall not subject them to excessive an undue abuse producing crushing of steel. Manipulation of piles to force them into proper position, if considered by the Engineer to be excessive, will not be permitted. Any pile damaged in driving by reason of internal defects, or by improper driving, or driven out of its proper location in excess of the allowable tolerance, or driven below the elevation fixed by the Drawings or by the Engineer shall be corrected by the Contractor without added compensation by one of the following methods approved by the Engineer for the pile in question:-

a) The pile shall be withdrawn and replaced by a new and, when necessary, longer pile.

6.10 RISEN PILES

a) Piles which have risen as a result of driving adjacent piles shall be re-driven to the requirements of the Engineer.

6.11 CUTTING OFF AND CAPPING PILES

a) Tops of foundation piles shall be embedded in the concrete footing or pile cap, with a minimum depth as shown on the Drawings. Piles shall be cut off level or as shown on the Drawings, at the elevation indicated on the Drawings. The length of pile cut-off shall be sufficient to permit the removal of all injured material. The distance from the side of any pile to the nearest edge of the footing shall be as shown on the Drawings. When the top elevation of a pile is below the elevation of the bottom of the cap, the pile shall, if approved by the Engineer, be built up from the butt of the pile to the elevation of the bottom of the cap by an approved method. The cuts shall be made accurately in clean, straight lines; care shall be exercised to avoid damaging the remaining pile and to insure full bearing between the footings (or caps) and piles. Payment of all driven piles shall be measured from the toe to the cut-of point of the pile.

SP 6.7

b) The Contractor shall submit to the Engineer for approval his proposed method of cutting off piles. Piles shall be driven in accordance with the specified criteria and as ordered by the Engineer, and shall not be overdriven to avoid cutting off, without the approval of the Engineer.

6.12 PRESTRESSED SPUN CONCRETE PILES

6.12.1 Description

This work shall comprise the supply and installation of prestressed spun concrete piles, inclusive of pitching and driving, lengthening and cutting and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

6.12.2 Materials

(a) Concrete

Unless otherwise specified, ordinary Portland cement shall be used for the casting of piles. The materials and workmanship shall be as specified under Section 4 of this Specification.

(b) Reinforcement

The prestressing tendons and the non-prestressing reinforcement of the piles including

workmanship shall be as specified under Sections 4 of this Specification.

(c) End Plates

Each end plate shall be machine-finished and provided with a chamfer to accommodation the welding when two lengths of pile are jointed.

6.12.3 Casting

The length of piles to be cast shall be as shown in the drawing or as directed by the Engineer. Based on the results of pile driving resistance and/or load tests carried out on piles driven on the site, the Engineer may from time to time order the lengths of piles to be modified.

Piles shall be hollow cylinders manufactured by the centrifugal casting process. Moulds shall be of

metal, well braced an stiffened against deformations caused by the hydrostatic pressure of the wet concrete while spinning. the metal forms shall have smooth joints and inside surfaces. The forms shall be accessible for adequate cleaning.

The spiral reinforcement shall be securely held to the longitudinal reinforcement during casting and

spinning. Any welding used shall not affect the strength of the prestressing tendons. The pile shall not be removed from the moulds until after the specified transfer strength is achieved. The external diameter and the thickness of the pile shall not be less than that shown on the Drawings

and shall be constant over the entire length of the pile and coaxial with the end plate at each end. After a pile has been cast, the date of casting, reference number and length shall be clearly marked with

indeletable marking on the top surface and on the head of the pile. In addition, each pile shall be marked at intervals of 0.5 m along its length before being driven.

6.12.4 Handling and Storage

The method and sequence of lifting, handling, transporting and storing piles shall be such that piles are not damaged. Only the designed lifting and support points shall be used.

All piles within a stack shall be in groups of the same length. Packings of uniform thicknesses shall be

provided between piles at the lifting points.

SP 6.8

6.12.5 Pitching of Piles

Piles shall be pitched accurately in the positions as shown on the Drawings. At all stages during driving and until the pile has set or been driven to the required length, all exposed piles shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling and damage to the piles.

6.12.6 Driving of Piles

Each pile shall be driven continuously until the specified set and/or depth has been reached, unless otherwise approved by the Engineer. The driving equipment used shall be of such type and capacity to the approval of the Engineer. A follower (long dolly) shall not be used unless otherwise approved by the Engineer.

A detailed record of the driving resistance over the full length of each pile shall be kept. The log shall

record the number of blows for every 0.5 m of pile penetration. The Contractor shall inform the Engineer without delay if an unexpected change in driving characteristics is encountered.

Where required by the Engineer, set shall be taken at approved intervals during the driving to establish

the behaviors of the piles. A set shall be taken only in the presence of the Engineer unless otherwise approved. The Contractor shall provide all facilities to enable the Engineer to check driving resistances. The final set of a pile other than as friction pile, shall be recorded as the penetration in millimeters per 10 blows. The temporary compression of the pile shall be recorded if required.

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral

displacement of the ground. When required, careful leveling from a datum unaffected by the piling shall be made on the pile heads already driven, before and after driving subsequent piles. Piles which have been displaced as a result of driving adjacent piles shall be redriven to the required resistance.

6.12.7 Lengthening of Piles

Where lengthening of piles is required, the details of the joint shall be as shown on the Drawings. When two lengths of pile are jointed, the end plates shall bear over their complete areas. Shims for packing shall not be accepted.

6.12.8 Cutting and Preparation of Pile Heads

When a pile has been driven to the required set or depth, the head of the pile shall be cut off to the level specified or shown on the Drawings. The Contractor shall submit to the Engineer for approval, his proposed method for cutting of piles. Pile heads shall be constructed to details as shown on the Drawings.

6.13 STEEL PIPE PILES

6.13.1 Description

This work shall comprise the supply and installation of steel pipe piles inclusive of pitching and driving, lengthening and preparation of pile heads, all in accordance with this specification and to the details shown in the Drawings.

6.13.2 Materials

All steel pipes shall comply with BS 6323 with regard to sectional dimensions and the steel shall comply with the requirements of BS 4360.

6.13.3 Manufacture and Storage of Steel Pipe Piles

(a) Welding

Unless otherwise specified, all welds shall be full penetration butt welds complying with the requirements of BS 5153.

SP 6.9

(b) Fabrication of piles

The root edge or root face lengths of piles that are to be butt welded shall not differ by more than 25% from the thickness of piles not exceeding 12mm in thickness; or by more than 3mm for piles exceeding 12mm in thickness. When piles of unequal thickness are to be butt welded together, the thickness of the thinner material shall be the criterion.

Pile lengths shall be set up so that the differences in dimensions are matched as evenly as

possible.

The length of piles to be supplied shall be as shown in the Drawings subject to revision by the Engineer. Based on the results of pile driving resistance and/or load tests carried out on piles driven on site, the Engineer may from time to time order the lengths of piles to be modified.

(c) Matching of pile lengths

Longitudinal seam welds and spiral seam welds of lengths of pipe piles forming a completed pile shall, whenever possible, be evenly staggered. However, if in order to obtain a satisfactory match of the ends of piles or the specified straightness, the longitudinal seams or spiral seams are brought closely to one alignment at the joint, then they shall be staggered by at least 100mm.

(d) Straightness of piles

Unless otherwise approved, the deviation from straightness shall not exceed 1/600 of a length not exceeding 10m. When two or more such lengths are joined, the deviation from straightness shall not exceed 1/960 of the completed length.

(e) Fabrication of piles on site

When pile lengths are to be made up on site, all test procedures and dimensional tolerances shall conform to the specification for the supply of pipe materials. Adequate facilities shall be provided for supporting and aligning the lengths of pile.

(f) Handling and storage

All piles within a stack shall be in groups of the same length and on approved supports. All operations such as handling, transporting and pitching of piles shall be carried out in a manner such that damage to piles and their coatings is minimized. Piles that are damaged during handling and transporting shall be replaced by the Contractor at his own expense. All damage and rejected piles shall be removed from the site forthwith.

(g) Marking of piles

Each pile shall be clearly marked with white indeletable marking showing its reference number and overall length. In addition, each pile shall be marked at intervals of 0.3 meter along its length before being driven.

6.13.4 Workmanship

(a) Welding procedures

The Contractor shall submit for approval full details of the welding procedures and electrodes with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the Engineer and shall be in accordance with the requirements of BS 4870.

(b) Welders’ qualification

Only welders who are qualified in the approved welding procedure shall be employed. Copies of certificates relating to welders’ tests shall be made available to the Engineer on request.

(c) Radiographs

During production of welded tube piles, at least one radiograph approximately 300mm long shall be required on each completed length as a spot check on weld quality. This shall be taken on a circumferential or longitudinal weld and its position shall be as directed by the Engineer.

For spirally welded piles, one of the following tests shall be carried out:

SP 6.10

(a) for tubes of wall thickness 12mm or less, three spot check radiographs, one at each end of each length of the tube as manufactured and one at a position to be chosen at the time of testing by the Engineer and spot check radiographs as required by the Engineer on the weld joints between strip lengths;

(b) for tubes of any wall thickness, continuous ultra-sonic examination over the whole weld, supplemented where necessary by radiographs to investigate defects revealed by the ultrasonic examination.

(d) Acceptance standards

If the results of any weld test do not conform to the specified requirements, two additional specimens from the same length of pile shall be tested. In the case of failure of one or both of these additional tests, the length of pile covered by the test shall be rejected.

6.13.5 Installation of Steel Pipe Piles

(a) Pitching and driving of piles

Pitching and driving of piles shall be in accordance with sub-section 1.3.4.1 to 1.3.4.2. Tolerances shall be in accordance to sub-section 1.2.

(b) Lengthening of piles

Unless otherwise approved, where lengthening of piles is required, the piles shall be jointed by butt welding along the entire periphery as detailed in the Drawings.

(c) Cutting and preparation of pile heads

When a pile has been driven to the required set or depth and before encasing in concrete, the pile shall be cut within 20mm of the levels shown in the Drawings and protective coatings shall be removed from the surfaces of the pile head 100mm above the soffit of the concrete. Pile heads shall be constructed to details as shown in the Drawings.

(d) Concreting of pile shaft

If concreting is specified or shown in the Drawings after the pile has been cut off to the specified level, the shaft shall be filled with concrete in continuous operation. The method of placing shall be approved by the Engineer.

6.14 PROTECTIVE TREATMENT FOR STEEL PIPE PILES

6.14.1 General

This section covers the surface preparation and application of protective coatings to the external surfaces of the steel pipe piles.

6.14.2 Standard Specification

All painting work shall be conducted generally in accordance with British Standard Specification B.S. 5493 “Code of Practice for Protective Coating of Iron and Steel Structures Against Corrosion”.

Surface preparation for painting shall be to British Standard B.S. 4232 “Surface finish of blast-cleaned steel for painting” or equivalent Swedish Standard SIS 05 5900.

6.14.3 Documents Required

This Specification together with the paint manufacturer’s instructions and the aforementioned standards shall govern the conduct of the painting. The Contractor will, therefore, ensure that he has sufficient copies of these documents for the use of his work force, who shall be acquainted with their provisions before the start of any work.

The Contractor’s copies of the required standards and instructions shall be made available for the inspection of the Engineer before or at any time during the painting operations.

SP 6.11

6.14.4 Manufacturer’s Standard Coatings

Items of equipment and fittings normally provided with a maker’s standard paint coating need not be differently coated provided that the coating is approved as equivalent to that given within this Section. If it cannot be so approved, it must be upgraded in a fashion or alternatively coated with a paint system the same as that given in this Specification or approved as equivalent.

No ‘air drying’ paint coating less than 250 micron thick or applied over a surface prepared by means other than abrasive blasting or pickling will be approved as suitable.

6.14.5 Personnel

All personnel shall be experienced and skilled and adequately supervised by the Contractor.

6.14.6 Paint Delivery

Unless otherwise agreed by the Engineer, all paints forming part of any one painting system shall be obtained from the same source.

Paint shall be supplied in sealed containers and shall be used in strict rotation.

Unless otherwise agreed by the Engineer, samples of paint not less than 2 litres capacity shall be submitted for testing to the Engineer or his nominated testing authority. The cost of testing shall be borne by the Contractor.

6.14.7 Paint Storage

Paint shall be stored in sealed containers in a lock-up store where it is not exposed to extreme temperature. The temperature of the store shall be kept between 4oC and 27oC. Any special storage conditions recommended by the manufacturer shall be observed.

Paint which has not been used within the ‘shelf life’ period specified on the containers or within 18 months of the date of manufacture, whichever is the lesser, shall be replaced.

At the end of each working period, paints with a limited ‘pot life’ shall be discarded. Other types of paint from painter’s kettles shall be returned to store and kept in sealed containers with not more than 10% ullage. Before it is re-issued for use, that paint shall be thoroughly mixed and no fresh paint or thinners shall be added.

6.14.8 Application of Paint

The Contractor shall submit to the Engineer, particulars including the manufacturer’s data sheets of the primers and paints he proposes to use. These shall be subject to the Engineer’s approval and shall not afterwards be varied without the Engineer’s written agreement.

Where called for by the Engineer, the Contractor shall carry out paint application procedure trials, either at the fabricator’s works or at site as appropriate, with the equipment and labour to be used in the Works. The Contractor shall supply suitable steel and sufficient primer and paints for the trials and must demonstrate his ability to apply each coat of paint of a designated paint system in accordance with the Specification and the paint manufacturer’s data sheet. No painting of the contract steelwork will be permitted until the procedure trials have been completed to the satisfaction of the Engineer. Any adjustment to the paint formulation shown to be required by the trials, other than an increase in the amount of thinners, shall be subject to approval by the Engineer and shall be made at the paint manufacturer’s works before the final stage of a paint procedure trial and before delivery of the first batch of paint.

All requirements of the paint manufacturer’s data sheets shall be complied with. Paints shall be supplied from the Contractor’s paint store to the painters ready for application, the only adjustment of formulation being as provided for in the preceeding paragraph. Any addition of thinners must be made in the store under the supervision of the Engineer and only as allowed under the manufacturer’s data sheet.

The method of applying the paint shall be determined during the paint application procedure trials. Any alteration in the method or application shall be subject to the prior approval of the Engineer. Successive

SP 6.12

coats shall have different shades for identification and each coat shall be thoroughly dry before application of a further coat.

If blast cleaning is carried out before fabrication, a prefabrication primer shall be used which is compatible with the specified protective treatments.

All prepared steel surfaces shall receive the specified first coating before any signs of rusting appear on the surface. In general, the period between preparation and the application of the first protective coating shall not exceed four hours but the Engineer, may at his discretion, extent or reduce this period depending on the prevailing atmospheric conditions. Surfaces which show any sign of rusting whatever shall be prepared again to the satisfaction of the Engineer.

6.14.9 Handling and Storage of Painted Steelwork

The Contractor will be required to exercise the maximum care in handling and transporting of protected steelwork so that damage to the coatings may at all times be avoided. The use of properly designed slings and soft non-adherent packs is required throughout. All steelwork shall be stored off the ground after preparation for painting and in conditions free from contamination of any kind and from abrasion or other damage. Polythene wrapped spacing shall be laid between the layers of stacked materials. Where cover is provided, it shall be ventilated.

6.14.10 Surface Preparation

Surfaces shall be prepared for coating as follows:-

a) burrs, fins at cut edges, weld spatter, etc., shall be dressed off;

b) contaminants such as oil and grease, crayon marks, etc., shall be removed with suitable solvents;

c) the surface shall be blast cleaned to B.S. 4232 Second Quality;

d) laminations and other steel surface defects revealed by blast cleaning shall be dressed and the area shall be reblasted; and

e) all dust, grit, shot, etc., shall be removed.

Note : British Standard B.S. 4232 “Second Quality” is equivalent to SIS 055900 grade SA 2½.

The maximum profile height of the blast cleaned surface shall not exceed 100 microns, excepting for the blast cleaning abrasive for shop operations which may be grit of a size that gives the blast profile required by the priming paint manufacturer’s instructions.

6.14.11 Repairs to Damaged Surfaces

Areas of paint which have been damaged during handling, storing, loading and off-loading, transporting and erecting shall be cleaned to bare metal by grit blasting, grinding wheels or other approved means and the edges of the undamaged paint bevelled with sandpapers to the required finish.

The full specified painting system shall then be re-applied and the new paint shall overlap the existing paint work by at least 50mm.

All steelwork which is to be painted in coal tar/epoxy which has been damaged or been stripped to permit welding shall be repaired using an equivalent approved coal tar/epoxy suitable for application on wet or damp surfaces. The steel surface shall be adequately cleaned as specified in B.S. 5493 and coated to provide the paint thickness corresponding to adjoining surfaces.

6.14.12 Inspection

No protective coatings shall be applied to the prepared steelwork before the surface has been passed by the Engineer or his representative who shall be kept fully informed concerning the programme and procedures to be adopted and adequate time shall be allowed for inspection within the agreed programme.

All stages of the work will be subject to full inspection by the Engineer up to the standard generally as given in British Standard B.S. 5493.

SP 6.13

6.14.13 Equipment and materials

All brushes, rollers, spray and blast equipment etc., shall be of good quality and maintained in good order.

Air for blasting and spraying shall be available in sufficient quantity at adequate pressure at the point of use. It shall be substantially free from water and oil. Filters and traps to collect water and oil shall be regularly cleaned and/or emptied.

Grit for cleaning shall be free from undesirable contaminants. It shall be of a suitable size as indicated in B.S. 4232 and when re-circulated, shall be maintained at a suitable size range.

6.14.14 Protective Treatment

This paint system refers to all structural steelwork of piles, System SK8 of B.S. 5493 Table 4K Part 1 Group K two pack chemical resistant paints.

a) Surface preparation Sa 2½.

b) Finish coats KF3 two pack epoxy or modified epoxy coal tar, nominal coating thickness 450 microns.

Total nominal system thickness is 450 microns. The finish shall not promote the spread of flame across its surface.

SP 7.1

SECTION 7 - METALWORK

TABLE OF CONTENT

PAGE NO. 7.1 GENERAL REQUIREMENTS SP 7.2 7.1.1 Scope SP 7.2 7.1.2 Reference Standards SP 7.2 7.1.3 Records SP 7.2 7.1.4 Working Drawings SP 7.2 7.2 MATERIALS SP 7.2 7.2.1 General SP 7.2 7.2.2 Structural Steelwork SP 7.2 7.2.3 Handrailing SP 7.3 7.2.4 Metal Ladders SP 7.3 7.2.5 Step Irons SP 7.3 7.3 WORKMANSHIP SP 7.4 7.3.1 Surface Preparation SP 7.4 7.3.2 Connections SP 7.4 7.3.3 Fabrication SP 7.4 7.3.4 Manual Cutting SP 7.4 7.3.5 Marking of Parts SP 7.4 7.3.6 Welders and Welding SP 7.4 7.3.7 Bolt Holes SP 7.5 7.3.8 Bolted Movement Connections SP 7.5 7.3.9 Works Erection SP 7.5 7.3.10 Galvanised Metals SP 7.5 7.3.11 Works Painting SP 7.5 7.3.12 Site Erection SP 7.6

SP 7.2

SECTION 7 – METALWORK

7.1 GENERAL REQUIREMENTS 7.1.1 Scope

This section covers the supply and installation of engineering metalwork as shown on the Drawings.

7.1.2 Reference Standards

The following standards are referred to in this section: BS 5950 The use of structural steel in building BS 497 Cast iron and cast steel BS 638 Arc welding power sources, equipment and accessories BS 639 Covered carbon and carbon manganese steel electrodes for manual metal-arc

welding BS 729 Hot dip galvanized coatings on iron and steel articles BS 3382 Electroplated coatings on threaded components BS 4190 Black hexagon bolts, screws and nuts BS 4360 Weldable structural steels BS 4871 Approval testing of welders BS 5135 Arc welding of carbon and caron manganese steels BS 5493 Protective coating of iron and steel structures against corrosion BS 6323 Steel tubes for general engineering purposes SIS 05 59 Pictorial surfaces preparation standards for painting steel structures

7.1.3 Records

Where material specified as being supplied by the Contractor, the following records shall be submitted for inspection:-

(i) detaled manufacturing drawings (ii) materials test certificates (iii) manufacturer’s catalogues

7.1.4 Working Drawings

Before fabrication commences the Contractor shall submit duplicate copies of general arrangement and fabrication drawings showing complete details for the Engineer approval. Sufficient copies of the final version of the drawings shall be submitted for distribution to all concerned parties.

The Contractor shall be responsible for the correctness of his shop details and for shop fittings and site

connections.

7.2 MATERIALS 7.2.1 General

The Contractor shall supply and install the items of metalwork as specified, together with all fixings, mounting brackets, locking screws, lifting keys and other accessories normally required for erection, permanent fixing and operation.

The Contractor shall not use fixings and other items for metalwork in which dissimilar metals in contact are liable for lead to galvanic action when placed in permanent contact with each other.

7.2.2 Structural Steelwork

Structural steelwork shall conform to the requirements of BS 5950 and, unless indicated otherwise on the Drawings, all hot rolled steel sections and plate shall be made from steel to BS 4360, Grade 43. Steel tubes

SP 7.3

to be used for structural purposes shall comply with BS 6323. All steelwork shall be obtained only from manufacturers who have received the prior approval of the Engineer.

Steelwork shall be thoroughly descaled to BS 4232 second quality and shall be painted with two coats of two

pack epoxy based red lead primer before leaving the manufacturer's works. Any damage to this coating shall be made good before erection.

Bolts, ragbolts, nuts and washers shall conform to BS 4360 as regards materials, BS 4190 as regards

dimensions and BS 3382 as regards standardisation on surface protection. Each bolt shall be provided with two washers and bolts shall be long enough to show a full thread through the nut after fixing.

Steel sections, plates and bars shall be ordered in sufficient lengths for samples to be selected from any

section, plate or bar for testing. The Contractor shall, when requested by the Engineer provide manufacturer's test certificates for steel to be used in structural steelwork.

7.2.3 Handrailing

Handrailing shall be fabricated from pipe sections extruded from stainless steel conforming to BS 304 or other materials as shown on the drawings.

Stanchions shall be provided at regular intervals of maximum 1.5 m or as per drawings. The upper rail

shall be 1000 mm above the finished floor level or 900 mm above the nosing line on stairways or shall be as shown on the Drawings. The intermediate rails shall be positioned as shown on the Drawings.

The handrailing, fixing and anchorages shall be designed to withstand a continuous horizontal load to

the top rail of 1.5 kN/m. Expansion joints shall be provided where lengths of handrailing exceed 18 m. Handrailing shall be flush jointed.

The Contract Rates for handrailing shall be measured as the length supplied and erected including

forming sections, welding, provision of fittings, erection and grouting up of pockets formed for stanchion bases in concrete.

7.2.4 Metal Ladders

Metal ladders shall be galvanised mild steel stainless steel or aluminium as shown on the Drawings. They shall generally have the following dimensions unless otherwise shown on drawings :-

- minimum thickness of stringer 12 mm - diameter of rungs 20 mm - rung spacing (uniform) between 230 mm and 260 mm - minimum clearance to wall or other obstructions 200 mm - maximum distance between stringer supports 3.0 m The stringers shall be sized to suit the height of ladder and the intervals of the stringer supports. Stringers

shall be drilled to receive the rungs which shall be welded to the stringers on each side of each stringer. The bottom ends of the stringers shall not be designed for floor fixing, but shall terminate at wall fixing supports at least 150 mm above the floor. All edges of stringers shall be ground smooth to remove burrs and sharp edges.

Ladders exceeding 3 m high shall be provided with safety hoops at intervals not exceeding 900 mm, with the

lowest hoop 2.5 m above the ladder foot. Landings of open mesh flooring and handrails as specified shall be provided at intervals not greater than 9 m.

Stainless steel which is specified for ladders shall conform to BS 390.

The Contract Rates for supplying and fixing ladders shall include for all stainless steel, nuts, bolts, stays, base plates, etc. necessary for fixing the ladders securely in position.

7.2.5 Step Irons

Step irons shall be made from 25 mm diameter stainless steel or galvanised mild steel bars to the shape and dimensions shown on the Drawings.

SP 7.4

7.3 WORKMANSHIP 7.3.1 Surface Preparation

The surfaces quality of cleaned steel shall generally comply to Swedish Standard SIS 05 5900. Generally this requires that all oil, grease and dirt shall first be removed by washing with white spirit, naphtha

or steam before the steel is cleaned using iron/steel grit or shot, to achieve a surface quality equal to SA 2½, as defined in Swedish Standard SIS 05 59 00, with a maximum surface profile of 100 microns.

Manual cleaning shall be confined to site and will be sanctioned by the Engineer only when blast or power

tool cleaning cannot be carried out. After removal of oil, grease and dirt using white spirit naphtha or steam, all rust, loose scale, welding slag and spatter shall be removed using tools such as wire brushed, vibratory needle guns or chipping hammers to achieve a surface finish equivalent to Visual Standard ST3, as defined in Swedish Standard SIS 05 59 00.

7.3.2 Connections

Connections of steel frameworks shall be bolted or welded as shown on the Drawings or approved by the Engineer.

Connections that have been fully dimensioned and detailed on the Drawings shall be fabricated as detailed.

Other connections shall be designed and detailed by the Contractor to comply with BS 5950 and specified loading requirements.

Duplicate copies of all calculations shall be submitted for approval before fabrication commences. Bolted joints subject to vibration shall be provided with lock nuts. In general, bolted or welded joints shall not be weaker than the connected members. Members in

frameworks meeting at a point shall, wherever practicable, have their centroidal axes meeting at a point so as to avoid eccentricity.

The ends of all columns shall be machined perfectly square and special precautions shall be taken to ensure

uniform bearing at all column bases, caps and splices. All column bases shall be positioned 25 mm above the concrete foundations on steel wedges and after the

stanchions have been plumbed and levelled. The intervening space shall be grouted with a 1:1 cement sand mortar.

The Contractor shall be responsible for the perfect fitting of all materials supplied and shall replace at his own

expense all materials which do not fit.

7.3.3 Fabrication

The standard of workmanship and general procedure to be followed during fabrication shall conform to BS 5950.

7.3.4 Manual Cutting

Thermal cutting of steelwork by hand will not be permitted without the prior approval of the Engineer.

7.3.5 Marking of Parts

Steelwork members shall be uniquely and indelibly marked to indicate the position and direction in which they are to be fixed.

7.3.6 Welders and Welding

Welding procedures and qualification of welders shall be in accordance with the requirements of BS 4871 and BS 5135.

SP 7.5

Electric arc welding power sources, equipment and accessories shall comply with BS 638. Electrodes for manual metal arc welding shall comply with BS 639.

Automatic or semi-automatic welding shall be adopted wherever possible. All welds shall be of Class 1

quality with proper fusion penetration, be sound, smooth, continuous and free from concavity, undercutting, weld spatter and porosity. In places of high stress concentration butt welds shall be ground off flush with the base metal and all internal welds shall be ground flush with the face of the linings.

Where stainless steel is welded to mild steel, tests shall be carried out to prove the quality of the welded

seams. Sample weld shall be prepared by each welder before he commences work on the fabrication and during

fabrication as required by the Engineer. Approval testing of welders shall comply with BS 4871. All fields welding shall be tested ultrasonically or by other method approved by the Engineer and all results

shall be recorded and made available to the Engineer. All welding work shall be executed under the most favourable working conditions. Weather covers shall be

provided where necessary. The Contractor shall provide facilities for inspection of welds at the factory or on Site.

7.3.7 Bolt Holes

Holes shall not be distorted or enlarged when making drifts. Any misalignment of holes shall be reported. If a faulty member is not rejected the hole may be reamed to its correct positions.

Bolt holes through hollow sections of tubes shall be sealed to prevent the ingress of moisture.

7.3.8 Bolted Movement Connections

The slotted hole shall be made wider than the unslotted hole, and connected using a shouldered bit with a spring washer placed under the head and the shoulder bearing onto the fraying surface off the unslotted member.

7.3.9 Works Erection

If required, the steel framework shall be temporarily assembled at the fabricator's works for inspection and, if considered necessary, for testing before delivery.

7.3.10 Galvanised Metals

All metals to be galvanised shall be done by the hot dip process to the full dimensions shown or specified and all punching, cutting, drilling, screw tapping, welding and the removal of burrs shall be completed before the galvanising process commences. No component which is likely to come into contact with oil shall be galvanised. Galvanising on iron and steel shall be to BS 729.

All galvanising shall be uniform, clean, smooth and as free from spangle as possible. It shall weigh not less

than 0.4 kg per square metre of area covered and shall not be less than 0.1 mm thick. All galvanised metal parts shall be protected from damage due to electrolytic action, rust and abrasion during

delivery, storage and erection. Minor damage shall be touched up with an approved zinc-chromate or other approved metallic compound but if, in the opinion of the Engineer, the damage to the galvanising is too severe or extensive, the part shall be removed and re-galvanised.

7.3.11 Works Painting

Coating materials shall be stored, prepared and applied in accordance with the manufacturer's instructions. The dry film thickness (DFT) of each coat shall not be less than specified for the type of paint. The thickness

of each coat shall be measured by one of the methods listed in BS 5493. Prepared surfaces of structural steelwork shall be primed at the fabricator's works with 2 coats of highbuild

zinc phosphate to a total DFT of 150 microns unless otherwise specified.

SP 7.6

Clean steelwork shall be kept dry, under cover, and primed as soon as possible after cleaning, in the case of

manually cleaned steel, on the same day; blast cleaned within 4 hours. Shop bolted connections shall be brought together whilst the final coat is still wet.

7.3.12 Site Erection

Before any work on erection is begun on Site, the Contractor shall submit for the Engineer's approval details

of the method of erection he proposes to use and shall incorporate any arrangements, or take precautions, directed by the Engineer. Notwithstanding these requirements, the entire responsibility for adequacy of the frameworks during erection and the correct fitting of all components shall rest with the Contractor.

All structural steel at the Site shall be stored and handled so that members are not subjected to excessive

stresses or damage. The positioning and levelling of all steelwork, the plumbing of stanchions and the fitting of connections shall

be made with accuracy in accordance with the Drawings.

SP 8.1

SECTION 8 - PAVEMENT

TABLE OF CONTENT

PAGE NO.

8.1 SUBBASE SP 8.2 8.1.1 Description SP 8.2 8.1.2 Materials SP 8.2 8.1.3 Construction Methods SP 8.2 8.2 CRUSHED AGGREGATE ROADBASE SP 8.3 8.2.1 Description SP 8.3 8.2.2 Materials SP 8.3 8.2.3 Construction Methods SP 8.4 8.3 BITUMINOUS SURFACING SP 8.4 8.3.1 Cut-Back Bitumen Prime Coat SP 8.4 8.3.2 Materials SP 8.4 8.3.3 Equipment SP 8.4 8.3.4 Construction Methods SP 8.6 8.4 ASPHALTIC CONCRETE BINDER COURSE AND WEARING COURSE SP 8.6 8.4.1 Materials SP 8.6 8.4.2 Mineral Filler SP 8.8 8.4.3 Bitumen SP 8.8 8.4.4 Anti-Stripping Agent SP 8.8 8.4.5 Asphaltic Concrete Mix Requirement SP 8.9 8.4.6 Equipment SP 8.9 8.4.7 Construction Methods SP 8.9

SP 8.2

SECTION 8 – PAVEMENT

8.1 SUBBASE 8.1.1 Description

This work shall consist of furnishing, placing, compacting and shaping subbase material on a prepared and accepted subgrade or lower subbase in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the Engineer.

8.1.2 Materials

Subbase material shall be a natural or prepared aggregate comprising crushed rock, weathered or fragmented rock, gravel or crushed grave, sand or a mixture of any of these materials. It shall have a small proportion of plastic or non-plastic fines and shall be essentially free from vegetative and other organic matter, expansive clay minerals and lumps of clay. The material shall conform to the following physical and mechanical quality requirements:-

i) the liquid limit shall be not more than 25%;

ii) the plasticity index shall be not more than 6;

iii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 35;

iv) unless otherwise specified on the Drawings or directed by the Engineer, the material shall have a CBR value of 30 or more when compacted to 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5kg rammer method) and soaked for 4 days under a surcharge of 4.5kg;

v) the gradation shall conform to one of the envelopes shown in Table 1 with the fraction passing the B.S. 75 µm sieve not greater than 2/3 of the fraction passing the B.S. 425 µm sieve.

Table 1 - Gradation Limits For Subbase Material

B.S. Sieve Size % Passing by Weight

A B C D E F

50.0 mm 25.0 mm 9.5 mm 4.75 mm 2.00 mm 425 µm 75 µm

100 - 30 - 65 25 - 55 15 - 40 8 - 20 2 - 8

100 79 - 95 40 - 75 30 - 60 20 - 45 15 - 30 5 - 20

- 100 50 - 85 35 - 65 25 - 50 15 - 30 5 - 20

- 100 60 - 100 50 - 85 40 - 70 25 - 45 5 - 20

- 100 - 55 - 100 40 - 100 20 - 50 6 - 20

- 100 - 70 - 100 55 - 100 30 - 70 8 - 25


Prior to placing any subbase material, the underlying subgrade (particularly the top 300mm of the subgrade) or lower subbase shall have been shaped and compacted in accordance with the provisions of the relevant sections of this Specification. Notwithstanding any earlier approval of finished subgrade or lower subbase, any damage to or deterioration of the subgrade or lower subbase shall be made good to the satisfaction of the Engineer before subbase is constructed.

Subbase shall be placed with equipment approved by the Engineer over the full width of the formation to the required thickness as shown on the Drawings or directed by the Engineer in one layer or more, each layer not exceeding 200mm compacted thickness. Where two or more layers are required they shall be of approximately equal thickness and none shall be less than 100mm compacted thickness. Each layer of subbase shall be processed as necessary to bring its moisture content to a uniform level throughout the material suitable for compaction, and shall then be compacted using suitable compaction equipment approved by the Engineer to not less than 95% of the maximum dry density determined in

SP 8.3

the B.S. 1377 Compaction Test (4.5kg rammer method). Compaction shall be carried out in a longitudinal direction along the carriageway, and shall generally begin at the outer edge and progress uniformly towards the centre on each side, except on superelevated curves where rolling shall begin at the lower edge and carried out in such a manner that each section receives equal compactive effort, all to the satisfaction of the Engineer. Throughout the placing, adjustment of moisture content and compaction of subbase material, care shall be taken to maintain a uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction of the Engineer. The subbase shall be finished in a neat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre length shall be not less than the required thickness. The top surface of the subbase shall have the required shape, superelevation, levels and grades, and shall be everywhere within the specified tolerances.

8.2 CRUSHED AGGREGATE ROADBASE

8.2.1 Description

This work shall consist of furnishing, placing, compacting and shaping crushed aggregate roadbase material on a prepared and accepted subgrade or lower subbase or subbase in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the Engineer.

8.2.2 Materials

Crushed aggregate roadbase material shall be crushed rock, or crushed gravel, or a mixture of crushed and natural aggregates, which is hard, durable, clean and essentially free from clay and other deleterious materials. The material shall conform to the following physical and mechanical quality requirements:-

i) the plasticity index shall be not more than 6;

ii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 30;

iii) the flakiness index when tested in accordance with M.S. 30 shall be not more than 30;

iv) not less than 80% of particles retained on the B.S. 4.75mm sieve shall have at least one fractured face;

v) the weighted average loss of weight in the sodium sulphate soundness test (5 cycles) when tested in accordance with ASSHTO Test Method T 104 shall be not more than 12%;

vi) the material shall have a CBR value of not less than 80 when compacted to 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5kg rammer method) and soaked for 4 days under a surcharge of 4.5kg;

vii) the gradation shall comply with the envelope shown in Table 2 for the type specified.

Table 2 - Gradation Limits for Crushed Aggregate Roadbase

B.S. Sieve Size % Passing by Weight

Type II Type II

50.0 mm 37.5 mm 28.0 mm 20.0 mm 10.0 mm 5.0 mm 2.36 mm 2.00 mm 600 µm 425 µm 75 µm

100 95 - 100

- 60 - 80 40 - 60 25 - 40 15 - 30

- 8 - 22

- 0 - 8

100 85 - 100 70 - 100 60 - 80 40 - 60 30 - 40

- 20 - 40

- 10 - 25 2 - 10

SP 8.4


Prior to placing any crushed aggregate roadbase material, the underlying subgrade or lower subbase or subbase shall have been shaped and compacted in accordance with the provisions of the appropriate Section of this Specification. Notwithstanding any earlier approval of finished subgrade or lower subbase or subbase, any damage to or deterioration of the subgrade or lower subbase or subbase shall be made good to the satisfaction of the Engineer before crushed aggregate roadbase is constructed. Crushed aggregate roadbase shall be placed to the required width and thickness as shown on the Drawings or directed by the Engineer in one layer or more, each layer not exceeding 200mm compacted thickness. There two or more layers are required they shall be of approximately equal thickness and none shall be less than 100mm compacted thickness. Spreading shall be done by a mechanical spreader approved by the Engineer or, if approved by the Engineer, by motor grader. Prior to spreading, crushed aggregate roadbase shall be processed as necessary to bring its moisture content to a uniform level throughout the material suitable for compaction. Spread material shall be maintained at the correct moisture content for proper compaction by sprinkling with water or drying as may be necessary, and shall be compacted using suitable compaction equipment approved by the Engineer to not less than 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5kg rammer method). Compaction shall be carried out in a longitudinal direction along the carriageway and shall generally begin at the outer edge and progress uniformly towards the centre on each side, except on superelevation curves where rolling shall begin at the lower edge and progress uniformly towards the higher edge. In all cases compaction shall be carried out in such a manner that each section receives equal compactive effort, all to the satisfaction of the Engineer. Throughout the placing, adjustment of moisture content and compaction of crushed aggregate roadbase material, care shall be taken to maintain a uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction of the Engineer. The crushed aggregate roadbase shall be finished in a neat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre length shall be not less than the required thickness. The top surface of the crushed aggregate roadbase shall have the required shape, superelevation, levels and grades.

8.3 BITUMINOUS SURFACING 8.3.1 Cut-Back Bitumen Prime Coat

(a) Description

This work shall consist of the careful and thorough cleaning of the surface of a prepared and accepted crushed stone roadbase and the furnishing and application to the cleaned roadbase surface of a cut-back bitumen priming material in accordance with these Specifications and the lines, dimensions and cross-sections shown on the Drawings.

8.3.2 Materials

The priming material shall be cut-back bitumen of grade MC-0 conforming to the requirements of MS 159.

8.3.3 Equipment

The equipment used by the Contractor shall include a power broom, a compressed air blower, a self-propelled pressure distributor for bituminous material, and as necessary, equipment for storing and heating bituminous material.

(1) Power Broom

The power broom shall be a rotary type specifically designed for sweeping road surface, and shall be approved by the Engineer.

SP 8.5

(2) Compressed Air Blower

The compressed air blower shall comprise a portable air compressor of 3 m3/min, capacity at 0.7 N/mm2 delivery pressure with a suitable hose and nozzle for blowing clean a road surface after power brooming and shall be approved by the Engineer.

(3) Pressure Distributor for Bituminous Material

The distributor shall be a purpose built model of recognized manufacture and shall be approved by the Engineer. It shall conform to the requirements described hereunder.

The distributor shall have a capacity of at least 4,000 litres of bituminous material and shall be equipped with a gas or oil fired heating system capable of heating a full charge of bituminous material to 180o C. The heating system shall be such that overheating of the bituminous material will not occur and shall be of a type in which flames from the burner do not come into direct contact with the casing of the tank containing the bituminous material. The tank shall be insulated in such a manner that when filled with bituminous material at 180o C and not heated, the drop in temperature shall be less than 3o C per hour. A thermometer shall be provided to measure material in the tank and shall be so arranged that the highest temperature in the tank is measured. The tank shall be fitted with an accurately calibrated dipstick or contents gauge and the pipe for filling the tank shall be fitted with an easily replaceable filter. The distributor shall run on pneumatic tyred wheels of such width and number that the load produced on the road surface when the vehicle is fully charged shall not exceed 12 kg/mm of tyre width. The vehicle shall be equipped with a 'fifth wheel' tacheometer system to accurately measure its forward speed during spraying operations. The distributor shall be equipped with a full circulation type spray bar with nozzles from which the bituminous material is sprayed on to the road surface uniformly over the full spraying width. The spraying width shall be variable in increments of not more than 100mm up to a maximum of 5.0 metres. The spraying pump shall be driven by a separate power unit and shall be equipped with an accurate pressure gauge and an accurate flow rate gauge or meter. On the suction side the pump shall be fitted with an easily replaceable filter. The bituminous material at even temperature and uniform pressure may be sprayed uniformly over the spraying width at controlled rates in the range 0.25 to 8.0 litres/m2 at normal distributor operating speeds, such that deviation from the prescribed rate of application shall not exceed 10%. The distributor shall also be equipped with a hand spraying system. The meters for the 'fifth wheel' tachometer system and the bituminous material pumping flow rate, pumping pressure and temperature shall be located in such a manner that the vehicle driver can easily read them while operating the distributor. The spray bar shall be controlled by a second operator riding at the rear of the vehicle in such a position that all the discharge sprays are in his good view. All measuring equipment on the distributor shall have been recently calibrated and accurate and satisfactory records of the calibrations shall be submitted to the Engineer. If in the course of the work the rates of application of bituminous material are found to be inaccurate, the distributor shall be withdrawn from the Works and recalibrated to the satisfaction of the Engineer before being returned to service. The Engineer may require such performance tests as he considers necessary to check that the distributor is operating satisfactorily. As directed by the Engineer, the Contractor shall make the distributor and its equipment available for such tests and shall supply all necessary assistance, materials, tools, testing apparatus, etc., all at the Contractor's expense.

(4) Storage and Heating Facilities for Bituminous Material

Tanks for storage of bituminous material shall have a capacity suited to the proposed rate of utilization of the material and the method and frequency of its delivery to the Works, all to the satisfaction of the Engineer. The tanks, and where necessary barrel decanters, shall be equipped with heating systems which provide for effective and positive control of the temperature of the bituminous material at all times up to the temperature required for utilization. The method of heating shall be such that neither flames nor the products of combustion shall come into direct contact with the bituminous material or the casing of its immediate container, and such that no portion of the bituminous material shall be subject to overheating.

SP 8.6


(1) General Conditions

Bitumen prime coat work shall only be carried out in dry, warm weather when the surface to be treated is essentially dry.

(2) Surface Preparation and Cleaning

Prior to applying the prime coat, the crushed stone roadbase shall have been shaped and compacted in accordance with the provision of Section 4.5. Notwithstanding any earlier approval of finished crushed stone roadbase, any damage to or deterioration of the roadbase shall be made good to the satisfaction of the Engineer before prime coat is applied.

Immediately prior to applying the bituminous material, the full width of the surface to be treated shall be swept using a power broom followed by a compressed air blower, and if necessary, scraped using hand tools, to remove all dirt, dust and other objectionable material, all to the satisfaction of the Engineer.

(3) Application of Bituminous Material

The bituminous priming material shall be sprayed on to the cleaned roadbase surface by means of a pressure distributor. Any area inaccessible to the distributor, spray bar shall be treated using the distributor's hand spraying system. The rates of application shall be as directed by the Engineer based on the results of test applications, but shall usually be in the range 0.5 to 2.0 litres per square metre. The temperature of the MCO cut-back bitumen shall be maintained in the range 35o C to 60o C during spraying operations. If necessary, in order to prevent the bituminous material from flowing on the sprayed surface, the prescribed prime coat shall be applied in two separate spraying operations. Where the condition of the treated surface indicates that it is necessary, bituminous material additional to that prescribed shall be applied as the Engineer shall direct. Prime coat shall be distributed uniformly over the surface to be treated without streaking; the quantities applied shall not deviate by more than 10% from those prescribed. Areas with insufficient bituminous material shall be resprayed as necessary to make up the deficiency, all to the satisfaction of the Engineer. The surfaces of structures, road furniture and trees adjacent to the areas being sprayed shall be protected in such a manner as to prevent their being spattered or marred by bituminous material. Bituminous material shall not be discharged into road drains, gutters, etc.

(4) Curing and Opening to Traffic

Prime coat shall normally be left undisturbed for at least 24 hours after application and shall not be opened to traffic until, in the opinion of the Engineer, it has penetrated the roadbase and cured sufficiently so that it will not be picked up by the wheels of vehicles. The Contractor shall maintain the prime coat, all to the satisfaction of the Engineer, until the overlying pavement course is constructed, which shall not be within 24 hours after the application of the bituminous priming material nor within such longer period as is required, in the opinion of the Engineer, for the prime coat to achieve maximum penetration of the roadbase and become fully cured.

8.4 ASPHALTIC CONCRETE BINDER COURSE AND WEARING COURSE

This work shall consist of furnishing, placing, shaping and compacting asphaltic concrete binder course and wearing course on a prepared and accepted bituminous or bitumen primed pavement course, and shall include the careful and thorough cleaning of surfaces which are to be covered with a bituminous tack coat. The work shall be carried out all in accordance with these Specifications and the lines, levels, grades, dimensions and cross-sections shown on the Drawings.

SP 8.7

8.4.1 Materials

Aggregates

Aggregate for asphaltic concrete shall be a mixture of coarse and fine aggregates, and if necessary mineral filler. The individual aggregates shall be of sizes suitable for blending to produce the required gradation of the combined aggregate. Coarse aggregates shall be material substantially retained on 2.0 µm sieve opening and shall be screened crushed hard rock, angular in shape, and free from dust, clay, vegetative and other organic matter, and other deleterious substances. They shall conform to the following physical and mechanical quality requirements:

(a) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 30,

(b) the weighted average loss of weight in the sodium sulphate soundness test (5 cycles) when tested in accordance with AASHTO Test Method T 104 shall be not more than 12%,

(c) the flakiness index when tested in accordance with M.S. 30 shall be not more than 30,

(d) the water absorption when tested in accordance with M.S. 30 shall be not more than 2%,

(e) the polished stone value when tested in accordance with M.S. 30 shall be not less than 40 (only applicable to aggregates for wearing course).

Fine aggregates shall be material passing a 2.0 µm sieve opening and shall be clean natural sand, screened quarry fines, or a mixture thereof. Other types of fine aggregate may be used subject to the approval of the Engineer. Fine aggregates shall be non-plastic and free from clay, loam, aggregations of material, vegetative and other organic matter, and other deleterious substances. They shall conform to the following physical and mechanical quality requirements:

(a) the weighted average loss of weight in the sodium sulphate soundness test (5 cycles) when tested in accordance with AASHTO Test Method T 104 shall be not more 12%,

(b) the water absorption when tested in accordance with M.S. 30 shall be not more than 2%.

The gradation of the combined coarse and fine aggregates, together with ordinary Portland cement added as an adhesion and anti-stripping agent and if necessary, any other mineral filler, shall conform to the appropriate envelope in Table 3. Table 3 - Gradation Limits for Asphaltic Concrete

Mix Type Binder Course Wearing Course

B.S. Sieve Size Percentage Passing by Weight

37.5 mm 28.0 mm 20.0 mm 14.0 mm 10.0 mm 5.0 mm 3.35 mm 1.18 mm 425 µm 150 µm 75 µm

100 70 - 95 56 - 81 48 - 65 32 - 58 20 - 42 12 - 28 6 - 16 4 - 8

100 80 - 95 68 - 90 52 - 72 45 - 62 30 - 45 17 - 30 7 - 16 4 - 10

The gradation envelopes in the above table are purposely wider than the tolerances for good works control of asphaltic concrete mixes. For each type of mix required in the works, the Contractor shall establish a job mix formula gradation which shall consist of a single definite percentage passing for each sieve size in the above table and shall produce a smooth curve within and essentially parallel to the appropriate gradation envelope. This job mix formula gradation then becomes the job control envelope, and this job control envelope must be totally within the limits of the appropriate gradation envelope in the above table.

SP 8.8

Notwithstanding compliance with other requirements of the Specification, limestone aggregates shall not be permitted.

8.4.2 Mineral filter

Mineral filler shall be portland cement and shall conform to the following grading requirements:

Table 4 - Mineral Filler for Asphaltic Concrete

Sieve Openings Percentage by Weight Passing

600 µm

150 µm

75 µm

100

90 - 100

70 - 100

8.4.3 Bitumen

Bituminous binder for asphaltic concrete shall be penetration graded bitumen of 80 - 100 grade conforming to Table 5 below: Table 5 - Bitumen Properties

Characteristics ASTM Test Method Penetration of Grades 80 – 100

Penetration at 25o C (1/100 cm)

D5 80 – 100

Loss on heating (%) D6 not more than 0.5

Drop in penetration after heating (%)

D6/D5 not more than 20

Retained penetration after thin-film oven test (%)

D1754/D5 not less than 47

Solubility in carbon disulphide or trichloroethylene (%) D2024 not less than 99

Flash point (Cleveland open cup) (deg. C)

D92 not less than 225

Ductility at 25o C (cm) D113 not less than 100

Softening point (deg. C) D36 not less than 45 and not more than 52

8.4.4 Anti-Stripping Agent

Ordinary Portland cement shall be added to the combined aggregate for asphaltic concrete to serve as an adhesion and anti-stripping agent. The amount of cement added for this purpose shall be 2% by weight of the combined aggregate. (Additional cement may also be added, if necessary, to serve as filler.) Ordinary Portland cement for this purpose shall conform to the requirements of M.S. 522, and shall be dry, free flowing and free from agglomerations at the time of use. Notwithstanding the use of ordinary Portland cement as an anti-stripping agent as specified above, the Contractor shall be responsible for ensuring that the bitumen binder adheres satisfactorily to the aggregate and does not strip from it during the service life of the asphaltic concrete. Accordingly the Contractor shall carry out bitumen stripping tests with the proposed aggregates to demonstrate to the complete satisfaction of the Engineer that the aggregates will perform satisfactorily in service with the specified bitumen binder. Such tests shall be carried out in accordance with AASHTO Test Method T 182, or such other test methods as the Engineer shall direct or approve. When AASHTO Test Method T 182 is used, the coated area at the end of the mixture's period of immersion in water shall be not less than 95%.

SP 8.9

The Contractor may propose to use an adhesion and anti-stripping agent other than ordinary Portland cement in addition to, or wholly or partially instead of the ordinary Portland cement specified above. Such agent shall be of a type approved by the Engineer and shall be thoroughly mixed with the bituminous binder all in accordance with the manufacturer's instructions. In such case the agent shall be added to the bitumen binder used in the bitumen stripping tests in the appropriate amount and manner. Aggregate which does not perform satisfactorily in the bitumen stripping tests, using the approved adhesion and anti-stripping agent when appropriate, shall not be used in asphaltic concrete.

8.4.5 Asphaltic Concrete Mix Requirement

The normal range of design bitumen contents by weight of mix shall be 5.0 - 7.0%. The mix shall conform to the requirements of the Marshall method of test and analysis as follows:-

Parameter Limits

Stability, S, kg

Flow, F, mm

Air voids in mix, %

Voids in aggregate filled with bitumen, %

Not less than 500

2.0 - 4.0

3.0 - 5.0

75 - 85

8.4.6 Equipment

The Contractor shall provide all the plant and equipment necessary for executing the work in accordance with these Specifications, and shall furnish the Engineer with such details of particular items of equipment, e.g. manufacturer, model type, capacity, weight, operating features, etc., as the Engineer shall require.


(a) General conditions

Asphaltic concrete paving work shall only be carried out in dry weather when the surface to be covered is dry, or if so specified, has received a bituminous tack coat which shall have achieved a satisfactory degree of tackiness, all to the satisfaction of the Engineer. All laying, rolling and finishing work shall be carried out during daylight hours, unless the Contractor shall have provided suitable flood-lighting for the job site, to the satisfaction of the Engineer. The Engineer may order the discontinuation of work on account of adverse weather, unsatisfactory condition of materials, equipment or surface to be paved, or such other conditions as he shall consider detrimental to the work.

(b) Surface preparation and cleaning

Prior to constructing an asphaltic concrete pavement layer, the surface to be covered shall have been prepared in accordance with the appropriate sections of these Specifications. Notwithstanding any earlier approval of this surface, any damage to or deterioration of it shall be made good before asphaltic concrete paving work is commenced. If the surface to be covered is not to be provided with a bituminous tack coat, then immediately prior to commencing asphaltic concrete paving, it shall be swept using a power broom followed by a compressed air blower, and if necessary scraped using hand tools, to remove all loose particles, dirt, dust and other objectionable material, all to the satisfaction of the Engineer. If the surface to be covered is to be provided with a bituminous tack coat, then this shall be applied all in accordance with the provisions of Section 1.4.7.

(c) Aggregate handling and heating

Each aggregate to be used in the asphaltic concrete mixes shall be stored in a separate stockpile near the mixing plant. Stockpiles of sand and other fine aggregates shall be kept dry using waterproof covers

SP 8.10

and other means as necessary. In placing the aggregates in the stockpiles and loading them into the mixing plant's cold aggregate feed bins, care shall be taken to prevent segregation or uncontrolled combination of materials of different gradation. Segregated or contaminated materials shall be rescreened or rejected for use in the works and removed from the mixing plant site. The aggregates shall be fed into the dryer at a uniform rate proportioned in accordance with the appropriate job mix formula. The rate of feed for each aggregate shall be maintained within 10% of the rate prescribed and the total rate of feed shall be such that the plant's screens shall never be overloaded. The aggregates shall be dried and heated so that when delivered to the mixer they shall be at a temperature in the range 150o C to 170o C when the binder is bitumen of penetration grade 80 - 100. If the binder is other than bitumen of penetration grade 80 - 100, the Engineer shall specify an appropriate range for the mixing temperature.

Immediately after heating, the aggregates shall be screened into four (or more) fractions which shall be separately sorted in the hot aggregate storage bins in readiness for mixing. Ordinary Portland cement and/or other mineral filler to be used in the mix shall be stored separately and kept completely dry. Its rate of feed into the plant shall be accurately controlled by weight or volumetric measurement, all to the satisfaction of the Engineer.

(d) Heating of bitumen

The binder shall be heated so that when delivered to the mixer it shall be at a temperature in the range 140o C to 160o C when the binder is bitumen of penetration grade 80 - 100. If the binder is other than bitumen of penetration grade 80 - 100, the Engineer shall specify an appropriate range for the mixing temperature.

(e) Mixing asphaltic concrete

The mixing plant shall be so coordinated and operated as to consistently produce asphaltic concrete mixes within the tolerances prescribed in these Specifications, all to the satisfaction of the Engineer.

(f) Mixing in batch plants

For each batch the screened hot aggregates shall be weighed out into the aggregate weigh hopper in accordance with the proportions prescribed in the appropriate job mix formula; the sequence of weighing out shall commence with the largest sized aggregate and progress down to the fines, unless the Engineer shall otherwise approve. Mineral filler shall be weighed out into the filled weigh hopper, where this is provided, or added last to the aggregate weigh hopper, in accordance with the job mix formula proportions. The hot binder shall be weighed out into the binder weigh bucket in accordance with the proportions prescribed in the job mix formula. The hot aggregates and filler shall be discharged into the pugmill and mixed dry for the dry mixing time prescribed in the job mix formula, which shall usually be in the range 5 to 10 seconds. The hot binder shall then be added and wet mixing performed for the wet mixing time prescribed in the job mix formula; this shall be sufficient in that all particles of aggregate are uniformly coated with bitumen, and shall usually be 45 seconds or more for dense graded mixtures. The volume of each batch shall be such that the tips of the pugmill paddle blades just break out of the mixture at the height of their action. After the completion of wet mixing, each batch of asphaltic concrete shall be discharged from the pugmill either into a storage hopper or directly into a truck for hauling to the paving site. Care shall be taken that no segregation of the mix occurs.

(g) Mixing in continuous mix plants

The screened hot aggregates and filler shall be fed continuously from their storage bins in accordance with the proportions prescribed in the appropriate job mix formula, combined in the plant, and fed continuously into the mixer. The hot binder shall be sprayed on to the combined aggregate as it enters the pugmill at the rate required to achieve the bitumen content prescribed in the job mix formula. The materials shall then be carried through the pugmill and in the process be thoroughly mixed by the action of the paddles, and discharged over the dam into the storage hopper. The mixing time shall be sufficient so that all particles of aggregate are uniformly coated with bitumen, and shall usually be 45 seconds or more for dense graded mixtures.

SP 8.11

The plant shall be so adjusted as to maintain the level of mixture in the pugmill such that the tips of the paddle blades just break out of the mixtures at the height of their action.

(h) Transportation of asphaltic concrete

Asphaltic concrete shall be transported from the mixing plant to the site of the paving works in loads of not less than 5 tons using tip-trucks. Except where asphaltic concrete is to be hand laid, it shall be discharged directly into the paver hopper, as required, from the tip-trucks. Care shall be taken in the truck loading, hauling and unloading operations to prevent segregation of the mix. During transportation, the asphaltic concrete shall be protected from contamination by water, dust, dirt and other deleterious materials. The temperature of asphaltic concrete immediately before unloading from the truck either into the paver hopper or on to the road for hand spreading shall be not less than 125o C when the binder is bitumen of penetration grade 80 - 100. If the binder is other than bitumen of penetration grade 80 - 100, the Engineer shall specify an appropriate minimum unloading temperature. Any load which has cooled below the specified temperature in the truck shall be rejected for use in the works and removed from the site of the works.

(i) Laying asphaltic concrete

The sequence of laying operations shall be planned in advance by the Contractor and approved by the Engineer. Generally each paving layer shall have a compacted thickness of not less than twice the nominal maximum aggregate size of the mixture, and not more than 100mm. Where applicable, e.g. on superelevated sections and on carriageways with cross-slope in one direction only, laying shall commence along the lower side of the carriageway and progress to the higher side. Laying shall not be carried out in a downhill direction along any section of the road.

As far as is practicable, laying shall be carried out using a paver approved by the Engineer. Hand-casting of bituminous mix on to the machine finished surface shall be kept to the practicable minimum necessary for correcting blemishes and irregularities. In any areas inaccessible to the paver, laying shall be carried out by hand methods using rakes, lutes and other hand tools all to the satisfaction of the Engineer. All laying of bituminous mix shall be such that after compaction by rolling the specified course or layer thickness and surface profile shall be achieved. Care shall be taken to achieve a uniform surface texture fee from indentations, ridges, tear marks or other irregularities and to prevent segregation of the mix. During laying operations the temperature of asphaltic concrete shall be not less than 110o C when the binder is bitumen of penetration grade 80 - 100. If the binder is other than bitumen of penetration grade 80 - 100, the Engineer shall specify an appropriate minimum laying temperature. Material which has cooled below the specified temperature before laying shall not be used and shall be removed from the site of the works. The Contractor shall provide accurate thermometers at the paving site at all times, and shall check the temperature of asphaltic concrete in the paver hopper at regular intervals and before laying restarts after each interruption of the paving operation. As far as is practicable, the paver shall be operated continuously and the supply of bituminous mix shall be regulated so as to enable continuous paving. Transverse joints in a paving lane shall be kept to a practicable minimum, and intermittent stopping and restarting of the paver shall be avoided as far as is practicable. Care shall be taken that no bituminous mix is placed on expansion joints at bridges, inspection covers for utilities ducts, drainage and sewerage manholes and the like, and that catchpits, drainage openings through kerbs, etc., remain properly open and serviceable. During laying operations, such areas and openings shall be protected by suitably shaped and secured boards or other materials approved by the Engineer, and compaction of mix in the immediately surrounding or adjacent areas shall be completed by hand methods, all to the satisfaction of the Engineer. Alternatively, bituminous mix shall be laid and compacted by hand methods as necessary around surfacing discontinuities of these types, all to the satisfaction of the Engineer.

(j) Construction joints

Existing bituminous surfacing which new bituminous mix is to adjoin shall be cut back to present a straight, vertical edge not less than 25mm deep and a smooth transition section not less than 0.5 metre long against which to lay the new material. The specified thickness of the new surfacing shall be built up gradually from the vertical joint to avoid any bumps or ridges across the carriageway. Where longitudinal or transverse joints are required in a layer of bituminous mix under construction, the material first laid and compacted shall be cut back to a vertical face for the full thickness of the layer, on a line satisfactory to the Engineer before the adjacent area is paved.

SP 8.12

At all construction joints a thin uniform coating of bitumen emulsion of grade RS-1 shall be brushed on to the vertically cut joint faces some 10 to 15 minutes before laying the next section of bituminous mix commences to ensure good bonding. Also all contact surfaces of kerbs, gutters, manholes, catchpits, etc., shall be similarly treated with a coating of bitumen emulsion before bituminous mix is placed against them. Construction joints in a layer of bituminous mix shall be offset from those in any immediately underlying bituminous layer by at least 100mm for longitudinal joints and at least 0.5 metre, where possible, for transverse joints.

(k) Compaction of asphaltic concrete

For each layer of asphaltic concrete, compaction by rolling shall commence as soon as after laying as the material will support the rollers without undue displacement; nevertheless the temperature of asphaltic concrete at the commencement of rolling shall be not less than 110o C when the binder is bitumen of penetration grade 80 - 100. If the bitumen is other than bitumen penetration grade 80 - 100, the Engineer shall specify an appropriate minimum rolling temperature. In any areas inaccessible to the rollers, proper compaction shall be carried out using vibrating plate compactors, hand tampers or other suitable means, all to the satisfaction of the Engineer.

Initial (or breakdown) rolling shall be carried out with an approved steel wheeled tandem roller or three wheeled steel roller. The principal heavy rolling shall be carried out with an approved pneumatic tyred roller immediately following the initial rolling; the pneumatic tyred roller shall be ballasted to an operating weight of not less than 15 tons and its tyre inflation pressure shall be not

� �less than 0.7 N/mm 2 . The final rolling shall be carried out with an approved steel wheeled tandem roller and shall serve to eliminate minor surface irregularities left by the pneumatic tyred roller.

All rollers shall operate in a longitudinal direction along the carriageway with their driven wheels towards the paver. Rolling shall generally commence at the lower edge of the paved width and progress uniformly to the higher edge, except that where there is a longitudinal construction joint at the higher edge, this shall be rolled first ahead of the normal pattern of rolling. Generally successive roller passes shall overlap by half the width of the roller, and the points at which the roller is reversed shall be staggered. However, when operating on gradients in excess of 4%, the breakdown roller shall not pass over any previously unrolled mix when operating in the downhill direction.

In all cases compaction shall be carried out in such a manner that each section receives equal compactive effort, all to the satisfaction of the Engineer. The steel wheeled rollers shall operate at speeds of not more than 5 kph and the pneumatic tyred roller shall operate at speeds of not more than 8 kph. No roller or heavy vehicle shall be allowed to stand on newly laid bituminous mix before compaction has been completed and the material has thoroughly cooled and set. Rolling shall continue as long as is necessary to achieve the appropriate requirement in the following table.

Type of Pavement Required Compacted Density

Binder Course 95 – 100% Marshall density

Wearing Course 98 – 100% Marshall density

Care shall be taken to prevent over-compaction of asphaltic concrete.

Within 24 hours of laying and compacting the bituminous mix, the Contractor shall cut core samples of not less than 100mm nominal diameter at locations selected by the Engineer. The rate of sampling shall be 1 sample per 500m2 of mix laid, but not less than 2 samples for the work completed in each paving session. These core samples shall be used by the Engineer to determine the thickness of the compacted layer of mix and the compacted density of the material in accordance with either ASTM Test Method D 1188 or ASTM Test Method D 2726, whichever is applicable.

(l) Finished asphaltic concrete

Asphaltic concrete binder and wearing courses shall be finished in a neat and workmanlike manner; their widths shall be everywhere at least those specified or shown on the Drawings on both sides of the centre-line. For a binder course or wearing course the average thickness over any 100 metre length shall be not less than the required thickness, and the minimum thickness at any point shall

SP 8.13

be not less than the required thickness minus 5mm. The top surface of a wearing or binder course shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances specified in Section 1.2.

(m) Opening to traffic

Asphaltic concrete shall not be opened to traffic until compaction has been completed and the material has thoroughly cooled and set in the opinion of the Engineer. This will usually be not less than 4 hours after the commencement of rolling. Where it is necessary to allow earlier use of the finished surface to facilitate the movement of traffic, the finished surface to facilitate the movement of traffic, vehicles may be allowed to run on the work after rolling has been completed, provided that speeds are restricted to 30 kph or less and sharp turning movements are prohibited.

SP 9.1

SECTION 9 - FENDERS

TABLE OF CONTENT

PAGE NO.

9.1 FENDER SP 9.2

SP 9.2

SECTION 9 – FENDERS

9.1 FENDERS

Fenders shall be supplied and fitted at the locations indicated on the drawings. The fenders shall be of the following manufacture and type: Manufacturer : Bridgestone Corporation Type : Super M Fenders Grade M2 Model : SM400H x 2.5m + 2.7m as shown on Drawing No. 20302/MS-1 Anchorages : Super Bolt M36 x 270mm length. Materials and components as per

Bridgestone Anchor Bolt’s details Alternative fenders of equivalent standard may be proposed subjected to approval. Where alternative fenders are proposed relevant details shall be supplied, including the name of the manufacturer, fender type and model, dimensions and anchorage details, energy absorption and force characteristics of the fender. Fenders and their associated anchorages shall have a high resistance to wear and shall be durable against the effects of weather, sunlight and salt water. Fender anchorages shall be installed strictly in accordance with the manufacturer’s instructions. Cast-in inserts shall be securely held in position by attachment to the formwork or templates during placing and curing of the concrete.

APPENDICES

APPENDIX A

LIST OF DRAWINGS

THE CONSTRUCTION AND COMPLETION OF THE PROPOSED EXPANSION PLAN OF SWINBURNE UNIVERSITY OF

TECHNOLOGY SARAWAK (SUTS) AT JALAN UPLANDS

LIST OF DRAWINGS

ITEM DESCRIPTION DRAWING NO. REV.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Cover

Drawings List

Locality and Layout Plan

Access Road Layout Plan

Access Road Cross Sections

Bypass channel Plan and Elevation

Bypass channel Layout Plan

Bypass channel Section Details

RC Pilecap Details (1)

RC Beam Details (1)

RC Beam Details (2)

RC Beam Details (3)

RC Deck Slab Details (1)

Walkway Details

Walkway End Joint Details

Miscellaneous Details

350mm dia. Prestressed Spun Pile Details

500mm dia. Prestressed Spun Pile Details

Borelog Details

APPENDIX B

BOREHOLE LOGS

tender document (sample).pdf

Documents

tender c

tender b

tender la

form of tender app

form of tender ft

summary of tender pre

summary of tender st

agreement words